basic facts report on design for plastic packaging ... · hand. design for recyclability is...

DesignforplasticpackagingrecyclabilityMepexConsultAS2017 1

BasicFactsReportonDesignforPlasticPackaging

Recyclability

Version0.207.04.2017


Contents1. INTRODUCTIONBYGPN.........................................................................................................................4

2. SCOPEANDRATIONALE..........................................................................................................................5

2.1 INTRODUCTION...........................................................................................................................................52.2 BUILDINGONINTERNATIONALKNOWLEDGE......................................................................................................52.3 PLASTICMATERIALSINPACKAGINGPRODUCTS...................................................................................................52.4 PACKAGINGPRODUCTSFORCONSUMERPRODUCTS............................................................................................62.5 GUIDELINESFORFILMANDRIGIDPLASTICPACKAGING........................................................................................62.6 RECYCLINGANDSORTINGTECHNOLOGY...........................................................................................................62.7 AMARKETFORRECYCLING............................................................................................................................62.8 STEPSOFRECYCLABILITY...............................................................................................................................7

3 USERGUIDE............................................................................................................................................8

3.1 DEFINITIONS...............................................................................................................................................83.2 STRUCTUREANDUSAGE................................................................................................................................83.3 RELEVANCE................................................................................................................................................8

4. GENERALGUIDELINES.............................................................................................................................9

4.1ADDITIVES........................................................................................................................................................94.1.1 CalciumCarbonate(CaCO3)andotherfillers....................................................................................10

4.2. BARRIERMATERIALS..................................................................................................................................114.2.1 EVOH................................................................................................................................................134.3.2 Polyamide/Nylon(PA)......................................................................................................................134.2.3 Sortingandrecyclingmaterialswithbarriers...................................................................................13

4.3 COLOURS.................................................................................................................................................144.3.1 Colourfulplasticpackaging..............................................................................................................144.3.2 CarbonBlack.....................................................................................................................................15

4.4 ALUMINIUM.............................................................................................................................................174.5 PAPER.....................................................................................................................................................174.6 PVC.......................................................................................................................................................174.7 ADHESIVES...............................................................................................................................................174.8 INKSANDPRINTING...................................................................................................................................184.9 SLEEVESANDLABELS..................................................................................................................................194.10 RESIDUES.................................................................................................................................................214.11 BIOBASED,OXO-DEGRADABLE,ANDBIODEGRADABLEPLASTIC...........................................................................21

5. PACKAGINGFILM.................................................................................................................................23

5.1 FILMAPPLICATIONS....................................................................................................................................235.2 LABELS....................................................................................................................................................235.3 ADDITIVESANDBARRIERS............................................................................................................................245.4 SORTINGANDRECYCLING............................................................................................................................25

5.4.1 PP-film..............................................................................................................................................255.4.2 LDPEfilm...........................................................................................................................................25

6 RIGIDANDTHERMOFORMEDPACKAGING............................................................................................27

6.1POLYPROPYLENE(PP)PRODUCTS........................................................................................................................276.1.1. PPapplications.............................................................................................................................276.1.2. Colours..........................................................................................................................................276.1.3. ClosureSystems............................................................................................................................286.1.4. Sleevesandlabels.........................................................................................................................28


6.1.5. AdditivesandBarriers..................................................................................................................296.1.6. SortingandRecycling...................................................................................................................30

6.2. HIGHDENSITYPOLYETHYLENE(HDPE)PRODUCTS...........................................................................................316.2.1. HDPEapplications........................................................................................................................316.2.2. Colours..........................................................................................................................................316.2.3. ClosureSystems............................................................................................................................316.2.4. SleevesandLabels........................................................................................................................326.2.5. AdditivesandBarriers..................................................................................................................326.2.6. SortingandRecycling...................................................................................................................33

6.3. POLYSTYRENE(PS)PRODUCTS......................................................................................................................346.3.1. PSapplications.............................................................................................................................346.3.2. Colours..........................................................................................................................................346.3.3. ClosureSystems............................................................................................................................356.3.4. SleevesandLabels........................................................................................................................356.3.5. AdditivesandBarriers..................................................................................................................356.3.6. SortingandRecycling...................................................................................................................36

6.4. POLYETHYLENETEREPHTHALATE(PET)PRODUCTS...........................................................................................376.4.1. PETApplications...........................................................................................................................376.4.2. Markets........................................................................................................................................386.4.3. Colours..........................................................................................................................................386.4.4. Closuresystems............................................................................................................................386.4.5. Sleevesandlabels.........................................................................................................................396.4.6. AdditivesandBarriers..................................................................................................................396.4.7. Sortingandrecycling....................................................................................................................40

7. ATTACHMENTS.....................................................................................................................................41

7.1. ABBREVIATIONSANDDEFINITIONS................................................................................................................417.2. DESCRIPTIONOFTYPESOFPLASTICS..............................................................................................................437.3. SORTINGANDRECYCLING............................................................................................................................45

7.3.1. NIRsortingtechnologyinsortingplants(MRF)............................................................................467.3.2. Washingandrecyclingtechnology...............................................................................................477.3.3. Outlinedescriptionofmarketforrecycledplastics......................................................................49

7.4. BIOBASED,OXO-DEGRADABLEANDBIODEGRADABLEPLASTICS...........................................................................517.4.1. Oxo-degradableplastics...............................................................................................................527.4.2. Biodegradableplastics.................................................................................................................527.4.3. Productionvolumesandapplications...........................................................................................527.4.4. Sortingandrecyclingofbioplastics..............................................................................................55

7.5. REFERENCES.............................................................................................................................................587.6. LISTOFPERSONALCOMMUNICATIONS...........................................................................................................60


1. IntroductionbyGPN

Whileacirculareconomywithhighrecyclingratesisanimportantgoal,theenvironmentalperformanceofpackagingsolutionsalwaysdependsontheentirevaluechain.Themostimportantfunctionofpackagingistosecurethattheproductreachesitsintendeduse.Theeffortstoreducefoodwasteshowhowtheproductgivespackagingleverageontheoverallenvironmentalperformance.

Atthesametime,sustainabilityandEU’sstrategiesdemandtransitionstowardscircularmaterialflows.Productandpackagingdevelopmentshouldfollowatwo-step,iterativeprocess.First,thesustainabilityoftheentirepackagingsolutionmustbeinvestigatedusinglifecyclethinking.Second,therecyclabilityandcircularityofthepackagingmustbeinvestigated,andpossibleimprovementsidentified.Thenbacktosteponetoevaluateifthepackagingcanbemademorerecyclablewithoutweakeningitsprimaryfunction.

FTIABandGrøntPunktNorgeAS(GPN)aretheleadingproducerresponsibleorganisations(PROs)inSwedenandNorway.Weworktosupportanddevelopcircularvaluechains.TheEUproposedveryambitiousgoalsforrecyclingofpackaginginDecember2015,andtherevisedframeworkdirectiveonwasteandthepackagingdirectiveisexpectedtobefinalisedduringfirsthalfyearof2018.Withhigherrecyclinggoals,addressingthelowrecyclabilityofplasticsiskeytofindingefficientsolutionstothetaskathand.Designforrecyclabilityisthereforeagoodinvestmentforindustryandtheenvironment,awin-win.Inmanycases,smalladjustmentscanhaveabigimpactonsortingandrecycling.

Withthisondesignforplasticpackagingrecyclability,wehopetoofferknowledgeandinspirationtoeveryoneinvolvedinplasticpackagingdesign.Thereportaimstobringknowledgeaboutthesortingandrecyclingindustryintothedesignprocess.Thecontentwillbecondensedintodesignforrecyclabilityguides,andcompanieswillbeinvitedtojoinprojectgroupsthattakeonspecificchallengesandpossibilitiesrelatedtoplasticpackagingrecyclability.

MepexConsulthaswrittenthisbaselinedocumentasanobjectiveanalysisbasedonthebestavailableknowledgetodayfrommanydifferentsources.

Goodluck!


2. ScopeandRationale

2.1 IntroductionGreenDotNorwayandFörpacknings-ochTidningsinnsamlingen(FTI)inSwedenhaveincooperationdevelopedasetofguidelinesthatpresentrecommendationsandsolutionstoproduceplasticpackagingthatisultimatelybasedonachievingincreasedmaterialrecycling.Thereisagreatneedtobetterunderstandwhathappenstoplasticpackagingaftercollectionwhenitissortedandrecycled.Thiskindofknowledgeisvitalwhendesigningplasticpackagingtobesortableandrecyclableinpractice.

Therearemanyfunctionalrequirementsforplasticpackagingthatcanbeconflictingwhenattemptingtoincreaserecyclability.Theserequirementsmustbefullyunderstoodandevaluatedupagainstoneanother.Suchrequirementsincludeforinstancethatplasticpackagingshallprotecttheproduct,andmaintainitsqualityandlifetime.Packagingcaninthiswaycontributetopreventingandreducingfoodwaste.Furthermore,thepackagingshallprovideinformationtotheconsumer,contributetoeffectivelogistics,havealowweight,andthuscontributetoanefficientuseofresources.

Anobjectiveanalysisonfactualdatafromeachstepinthevaluechainhasbeenemphasizedintheseguidelines.Clearrecommendationsaregivenwhereithasbeenpossible,andinareaswherethereismorethanonecorrectsolution,optionshavebeengiven.

TheguidelinesarebasedonexistingsortingandrecyclingtechnologiesforNorwegianandSwedishplasticpackagingproducts.Itisimportanttohighlightthattheexistingmarketandtechnologyisdynamic.Itisthereforecrucialthatthisguideberegularlyupdated.

2.2 BuildingonInternationalKnowledgeExistinginternationalguidelinesonthedesignofplasticpackaginghavebeenausefulbasisforthedevelopmentoftheseguidelines.Differentguidelinescangivevaryingrecommendationssoithasbeennecessarytothoroughlyreviewtheunderlyingassumptionsforeachrecommendation.SpecificNorwegianandSwedishcircumstancesintermsofpackagingusageandwastesolutionshavebeenemphasizedinthisprocess.

2.3 PlasticmaterialsinpackagingproductsTheseguidelinesincludeplasticpackagingproducts.Butwhatisplastic?Plasticsaremainlysyntheticpolymermaterials;alargematerialfamilywithmanyusageareas.Roughly330milliontonsofplasticwereproducedintotalworldwidein2016,andtheproductioncontinuestogrow.InEurope,plasticpackagingconstitutesca.40%ofallplasticproduction,ca.63%ofallplasticwaste,andca.83%ofallplasticthatisrecycled.Roughly50%oftheplasticmaterialinEuropethatisrecycled,isrecycledinthefarEast.

Plasticconsistsofmolecularchainswithdifferentmolecularweights.Biologicalresourcesareusedintheproductionofplasticmaterial,however,oilandthegasarethemostcommonresources.Biobasedandbiodegradableplasticsarediscussedinsection0

Incomparison,theproductioncapacityforbiobasedandbiodegradableplasticsisexpectedtobeca.6milliontons,wherebiobasedplasticsconstitute5milliontons.

ThemostimportanttypesofplasticsusedforpackagingproductsareLDPE,HDPE,PP,PETandPS(seelistoftypesofplasticsinChapter7.1.Theseplasticsarecalledthermoplasticsandcanberecycled,i.e.theycanbemeltedandmouldedintodifferentshapes.

Plasticscontainvariousadditivestogivethematerialdesiredproperties.Additivescanforinstancegivetheplasticanoxygenbarrierwhichprotectsthecontentofthepackagingproduct.Differenttypesofplasticscanbemixed,andfillerscanalsobeaddedtothematerial.Multimaterialpackagingproductsare


howevernotidealintermsofmaterialrecycling,andmonomaterialsshouldbepromoted.AdditivesandbarriermaterialsarefurtherexplainedinChapter4.

TherearestrictEUregulationsonplasticmaterialsusedforfoodcontact.1Thisalsoappliestoplasticsthatarerecycledfromwastetonewproducts.

2.4 PackagingproductsforConsumerproductsTheseguidelinesincludeplasticpackagingusedforconsumerproductscommonforNorwegianandSwedishhouseholds.Themainproductareaisgroceriesincludingfoods,butshallalsobeuniversalforotherindustriesthatoftenhavelesscomplicateddemandsfortheirpackaging.Packagingusedfortransportationhasbeendisregarded.

2.5 GuidelinesforFilmandRigidPlasticPackaging.ThereisagreatdealofknowledgeaboutthebuildingblocksofplasticpackagingmaterialsinNorwayandSwedenandtheirrecyclability:

• Roughly50%ofplasticpackagingwastefromhouseholdsisplasticfilm,mainlyintheformofpolyethylenefilm(LDPE),wellsuitedformaterialrecycling.Alargepartofthefilmconsistshoweverofseveralbarrierlayers;laminatedplastics.

• Theotherhalfconsistsofrigidplasticpackagingmadeofvariouspolymers,chieflyPP,PET,HDPEandPS.Rigidplasticsthatconsistofthesematerialsarenormallysuitedforrecycling.Differenttypesoftraysandcups,e.g.PET,areincludedasrigidpackaging(albeittheseproductsbeingthermoformedfilm).

2.6 RecyclingandSortingTechnologyIntheNordiccountriesplasticpackagingwasteiscollectedfromhouseholds,eitherseparatelyinitsowncontainer/bagorasinsomeplacesinNorwaytogetherwiththegeneralwaste.Thiscollectedplasticpackagingwasteisdependentonautomaticsortingtechnologytosorttheplasticintoitsdifferentfractions,achievinghighqualitymaterialrecyclingandreducingsignificantlossofusageareas.PlasticspackagingisprimarilysortedatlargefacilitiesinGermanyandSweden.Insomeplaces,materialrecoveryfacilities(MRFs)formunicipalwastehavebeenestablished.Thesefacilitiescanseparateplasticsfrommunicipalwaste.SeveralmunicipalcompaniesareplanningsuchplantsinNorway.

AnunderstandingoftheoptionsandlimitationsintheMRFsandtheirassociatedtechnologyiscrucialwhenconveyingknowledgeofplasticpackaginginthevaluechain.Inareaswhererecyclablematerialsareseparatedfromthegeneralwastestreamatthestart,therecyclablematerialsaresenttomaterialrecoveryfacilities(MRFs).

2.7 AMarketforRecyclingTherecyclingindustryforplasticpackaginginEuropeisstillinitsearlystages.Themarkethasthusfarconsistedofsmallandmediumsizedsortingfacilities.Manyofthesefacilitieswerebuiltforcollectedplasticwasteofhighquality,e.g.LDPEfilmandPETbottles,withsimplewashingandseparationprocesses.Technicalimprovementsinthisindustryarecrucialforhandlingplasticwasteofvaryingqualityandcomplexity,andforproducinghighqualityrawplasticmaterial.Therearevarioustypesofqualitiesoftherecycledrawplasticmaterialwheresomearemorevaluablethanothers.Overtimeitisnaturalthatthiswillchange.Betterpackagingdesignispartofthissolution.

1https://ec.europa.eu/food/safety/chemical_safety/food_contact_materials/legislation_en


2.8 StepsofRecyclabilityTherecommendationsgivenintheseguidelinesarebasedontheprinciplethatplasticmaterialsshouldforallpurposesberecycledintothesamematerialsforthesamepurpose,orforotherapplicationsand/orproducts.Thiswaythequalityofthematerialismaintained,asisitsmarketvalueandusageareas.Theplasticmaterialcanthereforeberecycledmultipletimes.Thiswillcontributetohighervaluerecyclinginthefuture.

Recyclingofplasticpackagingthatcontainsseveraldifferentplasticmaterials,colourpigmentsand/orbarriermaterialsrepresentsadown-gradeofthematerial,andthusnormallyalsothevaluewhichwilllimittheusageareas.Plasticsofhighqualityarerewardedwithhigherpricesonthemarketandareeasiertodistribute.


3 UserGuide3.1 DefinitionsAlistofthemostimportanttypesofplastics,relevantdefinitionsandanexplanationofabbreviationsusedintheguidelines,canbefoundintheappendix.

3.2 StructureandUsageRecommendationsanduniversalinformationforalltypesofplasticshavebeengatheredinaseparatesection,Chapter4,whilespecificinformationtailoredtodifferentplasticmaterialsaregatheredinothersubchapters;Chapter5forpackagingfilmandChapter6forrigidandthermoformedpackaging

Inthisreportgreentextboxesarepresentedatthestartofeachsubchaptertosummarisethetake-homemessagesofthatchapter.Therationaleforeachofthesemessagesisfurtherexplainedinthesamechapterorintheappendixwithreferenceslistedaccordingly.

3.3 RelevanceTherecommendationsintheseguidelinesarebasedonarangeofexternalsourcesthathavebeenanalysedandevaluatedagainstoneanother.Independentevaluationsweremadebasedonthecollectedmaterialfromexternalsourcesandwereconsultedwithexpertswithinplasticrecycling.

Theguidelinesweresenttoexternalreviewwitharangeofexpertsinthefieldofplasticpackagingproductionandplasticrecycling.

FTI(Sweden)andGreenDotNorwayareplanningtodeveloppopularversionofthisreporttopresentanddelivertotheirmembers.Theseguidelineswillrequireregularupdatesasthemarketandtechnologydevelopsandnewknowledgeisreadilyavailable.

Theguidelinescompriseseveralaspectsrelatedtodifferenttypesofmaterials.Itisimportanttounderlinethatthereisnoonebestsolutionorpackagingmaterialforallkindsofneeds.Eachmaterialhasitsstrengthsandweaknesses.Thechartbelowillustratesthedifferentpropertiesforsomeofthecommonpolymers.2

Figure1–Technicalconsiderationsforpolymerselection(RECOUP).

2RecouppresentationbyStuartFosteron“Futuretrendsinplasticpackaging,CapeTown2013


4. GeneralGuidelines

4.1Additives

SUMMARY–ADDITIVESAdditivesareusedinpackagingproductstoachievevariousdesiredproperties.Theprimaryfunctionofpackagingistocontain,protectandidentifytheproduct.However,thechoicesmadeatthedesignstagewillinfluencewhathappensinthesortingandrecyclingprocessesandthequalityofthenewrawmaterial.Itisthusimportantthatathoroughevaluationofavailablealternativesolutionstoadditivesshouldbeconsideredfordifferenttypesofplasticpackaging.Suchevaluationsmustbebasedonthoroughknowledge,includingunderstandingofrelevantsortingandrecyclingtechnologiesused.Calciumcarbonateisacommonadditiveinmanytypesofplastic.Thisheavymaterialwillquicklyalterthedensityofthepackagingandthusinfluencetheseparationprocess.Materialwithsuchfillerscanthereforebesortedoutbythewashingandnotrecycled.Alternatively,whennotsortedout,thesefillerscanharmrecyclingandthepropertiesoftherecycledmaterial.

Additivesaresubstancesthatareaddedtoplasticproductsbypolymerizationormodificationprocessestoobtainspecifictheproductproperties.Theseprocessesaltertheplasticcompoundbygivingitspecificcharacteristics.Additivesarealsousefulforloweringthetransitiontemperatureofapolymer,orbymakingaproductcheaperwiththeuseoffillers.Thetablebelowshowsabrieflistofexamplesofadditives.

Additives FunctionAnti-Counterfeiting Combatingcounterfeiting.Opticalbrightenersareanexampleofthistypeof

additive.Antimicrobials/Biostabilisers Helppreventdeteriorationofplasticmaterials.Antioxidants Helpprevent‘oxidation’(areactionbetweenthepolymerandoxygen)AntistaticAgents Helppreventbuild-upofstaticelectricchargeExternalLubricants HelppreventdamagetoplasticsorthemouldduringprocessingFillers/Extenders Naturalsubstanceusedtoimprovestrengthandlowercostofthematerial.

Usuallymineral-basedFragrances FragrancesanddeodorantsusedinavarietyofapplicationsHeatstabilisers Topreventdecompositionofthepolymerduringprocessing.ImpactModifiers Enablesplasticproductstoabsorbshocksandresistimpactwithoutcracking.InternalLubricants UsedtoimproveprocessabilityofplasticsbyincreasingtheflowabilityLightStabilisers Usedtoinhibitthereactionsinplastics,whichcauseundesirablechemical

degradationfromexposuretoUVlight.Pigments TinyparticlesusedtocreateaparticularcolourPlasticisers UsedtomakeplasticssofterandmoreflexibleProcessAids Usedtoimproveprocessabilityofplasticsbyincreasingtheflowability.Reinforcements Usedtoreinforceorimprovetensilestrength,flexuralstrengthandstiffnessof

thematerial.Oftenfibre-based.Table1–Listofadditivesandtheirfunctions.3

3http://www.bpf.co.uk/plastipedia/additives/default.aspx


TheEUCommissionstates4:

TherearehundredsofadditivesintheEUmarket,andtheirpresenceintheplasticscanvarylargely,fromafewpercentagesandupto50-60%.Someofthemaresoughtafterinrecycling,astheyaremuchneededintherecycledproduct(e.g.stabilizers,hardeners,plasticizers,structuralfillers).Someofthemmayhavenofunctionintherecycledproduct(UVabsorbers,flame-retardants)orneedcorrectionmeasures(odor,color).

Thehomogeneityofthepackagingproductismostimportantwhenitcomestorecycling;however,additivesprovideextraprotectionfortheproductinsidethepackaging,givingitprotectionand,ifabarriermaterialisadded,alongershelflife.5Compatibilizersarerelevantadditivesinordertoenhancerecyclingofdifferentpolymerblends.6

Plasticproductsandplasticwastecontainsdifferentadditivestoobtainthewantedpropertiesoftheproducts.TheEUCommissionselaboratesinbriefontheissueofadditivesandhazardoussubstancesinplasticwaste7:

Mostadditivesoftheoriginalwasteplastic,excepte.g.lubricantsorcatalysts,arenotconsumed,alteredordegradedduringthemeltingprocessofmechanicalrecycling(muchunlikeglassormetalrecycling),sothesearekeptandfoundinthepellets.Therecyclingofadditivesiswellidentified.Currently,onlyveryfewproblemsubstancesusedin/asadditiveshavebeenidentifiedasbearingenvironmentaland/orhealthrisk,notably:

• BisphenolA(curingagentinpolycarbonateandepoxyresins)• Lowmolecularweightphthalates(plasticizers):DEHP,BBP,DBD,DIBP,butnothighmolecular

weightonessuchasDINPandDIDP.• Halogenatedflameretardants• Toxicheavymetals(colorantsandstabilizers):Cadmium,Chromium6,LeadandMercury.

Someofthesesubstanceshavebeenvoluntarilyphasedoutbytheindustry,andtheyarepresentaslegacybutarenotbeingre-introducedintheplasticcyclesthroughvirginplastics.Thepresenceofthesesubstancesinwasteiscurrentlyhandledviaspecificlegislation,essentiallyWEEEandROHS,andtoacertainextentREACH(e.g.AnnexXVIIonrestrictionofusesofrecycledmaterial).ThepresenceofthesesubstancesinplasticproductsishandledbyREACH(andCLPforlabeling),thePOPsRegulation,andspecificfoodcontactlegislationforthistypeofuse.Shouldthesesubstancesbepresent,REACHistoensuretheprovisionofenvironmentandhealthinformationthroughthesupplychain.

4.1.1 CalciumCarbonate(CaCO3)andotherfillersFillersareoftenusedinconjunctionwithplasticpackagingproductstoreducetheamountofplasticsinaproduct,therebyreducingcostsandpartlytoimprovethepropertiesoftheplastic.Calciumcarbonateisusedasafunctionalfiller,andisoneofthemostimportantfillersthatisusedtoday.8

Calciumcarbonatewillnotinfluencethemeltingpointoftheplasticpackagingproduct;however,itwillheavilyinfluencethedensity–animportantpropertyforthesortingprocess.Thiscancauseproblemsinwhenmaterialsthatshouldfloat,endupsinkingbecausetheirdensityhaschanged.9TherearePS,PPandHDPEproductsonthemarketthathaveacontentofCaCO3ofupto50%.ThedensityofCaCO3is2.71 4EuropeanCommission,DGJointResearchCentre,mailcorrespondencetoallEoWstakeholdersbyA.Villanueva,11.05.115Commentfromparticipantatworkshop6http://www.dupont.com/products-and-services/additives-modifiers/polymer-additives/articles/polymer-compatibilizer-for-recycling.html7EuropeanCommission,DGJointResearchCentre,mailcorrespondencetoallEoWstakeholdersbyA.Villanueva,11.05.118MartinaLehmann,MAKSC9MartinaLehmann,MAKSC,AntonioFurfari


g/ccm,whichmeansthatsmallamountscanchangethepackaging’sdensitysubstantially.Tosplitthesefractionsfromtheplasticstream,theyrequireadensityoflessthan0,995g/ccmor1,07g/ccm.10Ifthedensityisabovethislevel,itwillbelostinthesortingprocesstotheresidualwastefraction.11HighlevelsofCaCO3canalsoaltertheviscosityoftheplastic,inadditiontoitstransparencyandcrystallisationproperties.12

ItispossibletoidentifyCaCO3withtheNIRdetectoranditispossibletoseparateplasticpackagingproductswithdifferentamountsofCaCO3inthem.13However,whenmultipletypesofproductsthatcontainCaCO3aremixedtogetheritisimpossibletoknowthefractionofCaCO3inthisfraction,eventhoughtheplasticmaterialisthesame.ThismakesitdifficulttorecyclebecausetherecouldbechangesinviscositybecauseoftheCaCO3content.

Nanofillerssuchasnanoclays,hydroalciteandmontmorillonitearethefastestgrowingmarketofplasticfillersandtheiruseisexpectedtoincreaseinthefuture.14

Insummary,theuseofadditives/fillerssuchascalciumcarbonate,talc,etc.inconcentrationsthatalterthedensitysuchthattheycauseforexampletheHDPEplastictosinkinwateroralterthepropertiesoftheregrindareundesirableandshouldbeavoided.15

4.2. BarrierMaterials

SUMMARY–BARRIERSBarriermaterialsareusedinpackagingproductstoachievevariousdesiredbarrierproperties.Theprimaryfunctionofpackagingistocontain,protectandidentifytheproduct.However,thechoicesmadeatthedesignstagewillinfluencewhathappensinthesortingandrecyclingprocessesandthequalityofthenewrawmaterial.Itisthusimportantthatathoroughevaluationofavailablealternativesolutionstobarriermaterialsshouldbeconsideredfordifferenttypesofplasticpackaging.Suchevaluationsmustbebasedonthoroughknowledge,includingunderstandingofrelevantsortingandrecyclingtechnologiesused.Variationsofthebarriermaterialspolyamide(PA)andPVdCshouldbeavoidedastheycandrasticallyreducethequalityoftherecycledplasticmaterialandcancreateproblemsintherecyclingprocess.NIRtechnologycan,toacertaindegree,identifymultilayermaterialsthatcannotberecycledandreducethefractionthatentersthisproductstream.EVOHisaneffectivebarriermaterialagainstoxygen,butitalsocreatessomechallengesintherecyclingprocess.AdditivesthatwillmakeEVOHmorecompatibleintherecyclingprocessofLDPEandPP-filmareunderdevelopment.PEThas,insomecases,goodbarrierproperties.Byusingthismaterialforpackagingproducts,theuseofotherlessidealbarrieralternatives,canbereduced.ThedownsidetotheuseofPETtraysisthatveryfewofthesearerecycledtodayastherearetechnicalandmarketingchallengestiedtotherecyclingofalltypesofPET,exceptforPETbottles.Bybetterdesign,theintentionistomakePETpackagingmorerecyclable.Inparallel,ofcourse,bettersortingandrecyclingtechnologiescancontributepositivelytoo.

10ThomasEtien,Danone11OliverLambertz,Tomra,PaulEastRECOUP12Commentfromparticipantatworkshop13OliverLambertz,Tomra14http://www.marketsandmarkets.com/PressReleases/plastic-filler.asp15RECOUPRecyclabilitybydesign


Barriermaterialsgivetheplasticspecificbarrierproperties.ThisincludesforinstancebarriersagainstUVradiation,oxygenandothergases.ThemostcommonbarriermaterialsareEVOH(Ethylenevinylalcohol),SiOxcoatings(siliconoxide),carbon-plasmacoating,polyamide(PA),PTNalloys,UVstabilisers,AAblockers,opticalbrightenersandoxygenbarriers.Variouslayersareaddedtogivetheproductspecificqualities-fivelayersarenotuncommoninmanypackagingproducts.16Itisdifficulttoreducetheamountoflayersinsomelaminatedtraysandfilmsifthebarrierqualitiesaretobemaintained.17Thetablebelowillustratesdifferentbarriermaterialsaccordingtotheirpermeationratesforwaterandoxygens.18

Figure2–Comparisonofpermeationsratesforvariousbarriermaterials.

PVOH,EVOH,PVdC,siliconeoxideandPETgarecoatingsthathavebeentestedMRFsandwereshowntohaveanegativeimpactontherecyclate.Theywereeitherdispersedintotherecyclateorremovedduringtheextrusionprocessasgases.19PVdCwasshowntohaveadetrimentaleffectonthequalityoftherecycledmaterialduetoitsthermaldegradationbelowthetemperaturesrequiredtomelttheconventionalpolymer.20PVdCisthereforeahighlydiscouragedadditivetouseinpolymers.

Crisppacketspresentadifficultpointofdiscussionbecausetherearenorightsolutionsforrecycling.Tomaintainthelifetimeofthecontent,analuminiumlayerisrequiredontheinsideofascrisppacket.Aluminiumwillcontaminatetherecyclateifitisnotseparatedfromthewastestream.Afterseparation,itwillbeincinerated.Itisthereforerecommendedthattheuseofaluminiumbeminimised.However,ithastobeacknowledgedthattodaytherearenoothermaterialsthatprovideasufficientbarrierthatcanbeusedforcrisppacketsandothersimilartypesofpackaging.However,newtechnologies,microwaveinducedpyrolysis,21mightreduceorsolvetheseproblemsinthefuture,e.g.removethealuminiumandrecycleit.

16Commentfromparticipantatworkshop17Commentfromparticipantatworkshop18Fraunhofer-Institut19McKinlay,R.andMorrish,L.(2016).REFLEXProject–ASummaryReportontheResultsandFindingsfromtheREFLEXProject.AxionConsulting.20McKinlay,R.andMorrish,L.(2016).REFLEXProject–ASummaryReportontheResultsandFindingsfromtheREFLEXProject.AxionConsulting.21ENVALtechnologiesdescribedinRECOUPRecyclabilitybydesign,page64


4.2.1 EVOHEVOHisacopolymerandisthedominatingadditiveusedinplasticspackagingtoday,especiallywhenitcomestobarrierproperties.22Itgivesgoodcompatibilityandisoftenusedincombinationwithotheradditives.23Itisusedasathinlayer,normally1-2%ofthetotalmaterial,andgivesagoodoxygenbarrier.24AlthoughtotalquantitiesofEVOHusedaresmall,itisusedinawiderangeofproducts.IfPEweretohavethesamebarrierqualitiesasatypicalEVOHlayer,thePElayerwouldhavetobe6mthick.25

EVOHhasameltingtemperatureof165-185°C,butthetemperaturevariesfordifferentadditives.Thiscancauseproblemsintherecyclingprocessifdifferentmaterialsmeltatdifferenttemperatures.26IfEVOHistheonlyadditiveinthepackagingmaterial,therecyclingprocessiseasier.27EVOHisverywidespreadinplasticpackaging;however,thereisevidenceofachangetowardstheuseofPETfilmtoprovidefoodprotection.28

ForPETbottles,EVOHisnotrecommendedbyEPBPasEVOH,above500ppm,deterioratethemechanicalpropertiesoftherecycledmaterial.

4.3.2 Polyamide/Nylon(PA)ManytypesofPAareusedasbarriermaterialsinplasticpackagingproductstoday.29PAitselfisnotabarriermaterial,butPA-O,orientatedPA,isagoodbarrier.30TheproductionoforientatedPAhappensbystretchingtheplasticinbothdirectionsgivingitacrystallinestructure.31

PAlaminateshavebeentestedintherecyclingfacilityandfoundtobeproblematic.PAisatoughmaterialthatbecomesfluffywhenshredded.Italsohasahighmeltingtemperature,220°C,whichmeansitwilloftencreatelumpsintherecyclateifthemeltingtemperatureofothermaterialsislower.32Thesequalitiesmakeitdifficulttoextrudeatlevelswithmorethan5%PA.33PAshouldparticularlybeavoidedincombinationwithEVOHandLDPEbecauseofthedifferentmeltingtemperatures.34

4.2.3 SortingandrecyclingmaterialswithbarriersThosebarriersthatcausetheleastharmtotherecycledfractionarethosethathavealowmeltingpoint.35Thematerialwillthenbesuretomeltintherecyclingprocess.Therearemanytypesoflaminatedfilmwithdifferentbarrierqualitiesandmanyofthesehaveahighrecyclingpotential.However,thechallengetodayisthattheindividualamountofeachtypeoflaminatedfilmistoosmalltobesortedandtherecoveryrateisnegligible.36

22Commentfromparticipantatworkshop23MartinaLehmann,MAKSC24Commentfromparticipantatworkshop25Commentfromparticipantatworkshop26MartinaLehmann,MAKSC,AntoninoFurfari27Commentfromparticipantatworkshop28Commentfromparticipantatworkshop29MartinaLehmann,MAKSC30Commentfromparticipantatworkshop31Commentfromparticipantatworkshop32Commentfromparticipantatworkshop33McKinlay,R.andMorrish,L.(2016).REFLEXProject–ASummaryReportontheResultsandFindingsfromtheREFLEXProject.AxionConsulting.34MartinaLehmann,MAKSC35OliverLambertz,Tomra36OliverLambertz,Tomra


PET/PElaminatesproduceaninhomogeneousmixintherecyclingfacility,resultinginaweakerstrengthandamorebrittlestructurethanPP/PE.PET/PElaminatesshouldthereforenotenterthePE/PPmechanicalrecyclingstream.37

Studieshaveshownthatthepresenceofaluminiumonapolyolefin(PO)recyclatecausesadegreeofweakeningofthematerial,makingitmorebrittle.Thissuggeststhatitisnotsuitableformechanicalrecycling.38

4.3 Colours

SUMMARY–COLOURSPlasticpackagingcanbetransparentorallkindsofcolours.Generally,packagingthatistransparentispreferredbecauseithasmorepotentialtoberecycledtoawidevarietyofapplications,sothevalueoftherecyclateishigher.TheNIRdetectorcanalsosometimeshavedifficultiesidentifyingproductsthataredarkincolour.Colouredpackagingwithsolid,darkcolourswillhavefewerpossibleapplicationsafterithasbeenrecycled.ForPETinparticular,thereisalimitedmarketfordarkcolouredrecycledmaterial.Forpolyolefins,colourantscaninsomecaseshaveanegativeimpactontherecyclingprocessandthegranulates.UseofthepigmentcarbonblackisproblematicbecausetheNIRtechnologycannotidentifythematerial.Otheravailabletechnologyiscurrentlyevaluatedasnotrelevantforthispurpose.Thereisaclearrecommendationthatthepigmentcarbonblackshouldbephasedoutasfaraspossible.

4.3.1 ColourfulplasticpackagingThecolourofaproductisimportantbecauseitisusedtomarkettheproduct.Variouscoloursappealtotheconsumerindifferentways.However,thecolourofaplasticpackagingproductwillinmanycasesalsodeterminewhetheraproductcanberecycledornot.Colourinterfereswiththemechanicalrecyclingprocessofaproductinvariousways.Gassesfromthedyescanforinstanceexhaustfromtheproductintherecyclingfacility.Inordertohandlethis,aproperdegassingsystemisneeded.39

Thecolourwillalsodeterminetheendmarketforaproduct.Stronglycolouredplasticmaterialhasamuchlowereconomicvaluethantransparent,non-pigmentedplastics.Manypackagingproductstodayaretransparent,ortheyhavelight,translucentcolours.Unpigmentedcontainersarepreferredtopigmentedforpackagingproductsasitmakesiteasierfortheconsumertoidentifytheproducttheyarepurchasing.

Intherecyclingmarket,unpigmentedpackagingmaterialispreferredandtheamountofcolourinpackagingproductsshouldbeminimised.40However,thisdependsonthematerialofthepackagingproduct.Theendmarketsdifferbetweenproducts,dependingonthequalityoftheproduct,itscolour,andtheapplications.TranslucentPET,forinstance,hasamuchhighervalueintheproductchainthan

37McKinlay,R.andMorrish,L.(2016).REFLEXProject–ASummaryReportontheResultsandFindingsfromtheREFLEXProject.AxionConsulting.38McKinlay,R.andMorrish,L.(2016).REFLEXProject–ASummaryReportontheResultsandFindingsfromtheREFLEXProject.AxionConsulting.39OliverLambertz,Tomra40K-online(2016).PlentyofPotentialforRecycling.PressRelease.Availableat:http://www.k-online.com/cgi-bin/md_k/lib/all/lob/return_download.cgi/FA02_Recycling_long_version_Logo_en.pdf?ticket=g_u_e_s_t&bid=3186&no_mime_type=0


colouredPET,whilstcolouredPPhasasimilarvaluetothatoftranslucentPP.ThisisfurtherexplainedinChapter0onPPandChapter1onPET:

Inmanycases,productswithsolid,opaquecoloursareproblematicbecausetheyhavefewerpossibilitiesintheendmarket.41Ifaproducerchoosesanopaquecolour,itispreferredthattheyminimisetheuseofothercoloursintheproducttokeeptherecycledstreamasuntaintedaspossible.Mixingcolourswilllowerthevalueoftherecyclateandreducetheapplicationsitcanbeusedfor.

COLOURS Nocolouring Light,translucentcolours Strong,solidcolours CarbonblackHDPE Ideal Yes Notideal NoPET Ideal Yes No NoPP Ideal Yes Notideal NoPS Ideal Yes Notideal NoLDPE Ideal Yes Notideal No

Table2–Compatiblecoloursforplasticpackagingofdifferentmaterialtypes.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

Certainmachinescan,whenspecified,readcolours.SuchmachinesareoftenusedforidentifyingdifferentcolouredPETbottles.42However,inmanyMRFs,heavilycolouredplasticcaninterferewiththeautomatedsortingmachinery.HeavilycolouredplasticsarestronglylightabsorbingandtheNIRdetectorcouldhavedifficultyidentifyingthenatureoftheplastic.43Heavycolours,metalliccolours,andcarbonblackarethereforelistedasunfitcoloursforpackagingproductsforallmaterialsandcategoriesofpackaging.

Someproducersandrecyclershavediscussedtheuseofacoatingontheoutsideofapackagingproduct,insteadofdyingthematerialitself.Ifthiscoatingcanberemoved,thenthevalueoftheuncolouredplasticproductwillremainhigh.Theseproductswouldthenhavetoundergoawashingprocesspriortosorting,somethingthatwouldrequirereconstructionsintherecyclingfacilities.44Testsareunderway;however,thereisuncertaintyastowhethertheNIRscannercanseethroughthiscoatingasitmaybetoothick.

4.3.2 CarbonBlackCarbonblackisthenameofthepigmentthatgivesplasticpackagingitsblackcolour.Manufacturershavebeenusingcarbonblackbecauseitisanattractivepackagingcolour.Itcreatesacontrastbetweenthepackaginganditscontents,whichmakesthefoodmoreappealingtotheconsumer.CarbonblackhasexcellentUVbarrierpropertiesandisalsotheleastcostlywayofgivingplasticstheirblackcolour.45

ThepigmentcarbonblackisproblematicbecausetheNIRdetectorscannotidentifythepolymerintheMRF.Thisfractionisthereforenotsortedouttotheplasticstreambutgoesintoanunidentifiablefractionthatconsistsofmunicipalsolidwastewherethematerialisincinerated.

Manyretailers,suchasWalmart,haveannouncedthattheywillremovecarbonblackfromtheirpackagingbecausetheseproductsendupinthemunicipalsolidwastefraction.46Manyorganisations,industriesandbrandownerssuggestamoveawayfromtheuseofcarbonblackaltogetherbecauseexistingtechnologydoesnotallowittobesorted. 41OliverLambertz,Tomra42OliverLambertz,Tomra43RECOUP(2016).PlasticPackaging.RecyclabilitybyDesign.TheEssentialGuideforallthoseInvolvedintheDevelopmentandDesignofPlasticPackaging.http://www.recoup.org/p/130/recyclability-by-design44Commentfromparticipantatworkshop45PlasticZero(2012).CarbonBlackPlastic–ChallengesandIdeasforEnvironmentallyFriendlyAlternatives.Availableat:http://www.plastic-zero.com/media/58691/sort_plast_brochure_final_en.pdf46Walmart(2016).SustainabilityPackagingPlaybook.Aguidebookforsupplierstoimprovepackagingsustainability.Presentation.


Therehavebeenexperimentstoseewhethertherearealternativestosolvethechallengewithcarbonblackforpackagingproducts.TheseprojectsfocusonchangingthetechnologyintheMRF,oralteringthepropertiesoftheplasticmakingitvisibleintheNIRdetector.However,therearedebatesastowhetherthefocusshouldbeonchangingtheproductionoftheproduct,orthesortingtechnology.

Therearealternativepigmentsavailabletocreateblackplastic,insteadofcarbonblack.ThesealternativepigmentscanbeviewedbyNIRdetectorsandthematerialcanbesortedintoitscorrectfraction.Thesealternativepigmentsarehowevernotfullydeveloped,andtheyareoften4-5timesmoreexpensivethancarbonblack.However,itisunclearhowthispricedifferenceinfluencesthepriceofthefinalproductandwhetherthispricemakesituneconomicalforusebyproductmanufacturers,retailersandpackagingmanufacturers.47NovelNIRdetectableblackcolourantshavebeenshowntoworkwithPET,PP,HDPE,PSandPVCinlarge-scaletrialsatrecyclingfacilities.48Thestudyresolvedthatthedetectableblackcolourantsneedtobematchedwiththepolymer.49ThetrialsconcludedthatalternativecolouranttechniqueswouldallowforsortingofblackpackagingwithexistingNIRtechnology.50

Thequestioniswhethertochooseadifferentpigmentaltogether,ortoaddamarkertotheproduct.Themarkercouldmaketheplastic,colouredbycarbonblack,visibletotheNIRdetector.Thiswayexistingtechnologycouldstillbeused,withjustminormodifications.51

Athirdoptionistoimprovethesortingtechnologies,eventhoughthisisthemoreexpensiveoption.ManyoptionsforcarbonblackdonotworkwithexistingNIRtechnology.52Newseparationtechnologies,MIRscanners,useadifferentspectrumtoidentifytheplastic-themediuminfraredspectrum.Carbonblackcanintheorybeidentifiedandseparatedbythesescanners;however,thetechnologyisstillverynewandcosts5-6timesthepriceofregularNIR.53PlasticZero(2012)statesthatthistechnologywillnotbecommonlyadoptedatrecyclingfacilitiesforatleastanother5years.54

Therearetwotechnologicalalternativestosortingcarbonblackplastic:

1. Blackscan:alaserscanstheconveyorbeltandsortsoutdarkcolouredandblackplastic,regardlessofmaterialtype,whetherit’stextiles,metalorcarbonblackplastic.Thelasercannotdifferentiatebetweenmaterialtypes.

2. Blackeye:blackeyetechnologyisbasedonNIRandcandifferentiatebetweenmaterials.However,thistechnologyismoreusedforplasticgranules.Thistechnologyisnotextensiveintheindustrybecausegranulesdonottendtobeblack.Italsodoesnotsortthematerialtypesproperlyandisdependentonhavingaconventionaldensityseparationprocesstofurtherdividetheplasticmaterials.55

Thesenewtechnologiesrequireasubstantialamountofenergyandareassociatedwithahigherriskoffire.Existingfacilitiesalsoneedtobereconstructed.56

47PlasticZero(2012).CarbonBlackPlastic–ChallengesandIdeasforEnvironmentallyFriendlyAlternatives.Availableat:http://www.plastic-zero.com/media/58691/sort_plast_brochure_final_en.pdf48Wrap(2011).DevelopmentofNIRDetectableBlackPlasticPackaging.Dvorak,R.;Kosior,E.andMoody,L.ofNextekLimited.Oxon.49Wrap(2011).DevelopmentofNIRDetectableBlackPlasticPackaging.Dvorak,R.;Kosior,E.andMoody,L.ofNextekLimited.Oxon.50Wrap(2011).DevelopmentofNIRDetectableBlackPlasticPackaging.Dvorak,R.;Kosior,E.andMoody,L.ofNextekLimited.Oxon.51OliverLambertz,Tomra52OliverLambertz,Tomra53PlasticZero(2012).CarbonBlackPlastic–ChallengesandIdeasforEnvironmentallyFriendlyAlternatives.Availableat:http://www.plastic-zero.com/media/58691/sort_plast_brochure_final_en.pdf54PlasticZero(2012).CarbonBlackPlastic–ChallengesandIdeasforEnvironmentallyFriendlyAlternatives.Availableat:http://www.plastic-zero.com/media/58691/sort_plast_brochure_final_en.pdf55OliverLambertz,Tomra56OliverLambertz,Tomra


Itiseasiertochangetheproductionoftheproduct,usingalternativepigmentstocarbonblack.Thiswaythecostsofnewtechnologyandthedangerthesetechnologiesbringwiththemisavoided.57However,conversationswithpackagingproducersindicatethatalternativepigmentsarenotreadilyavailableeitheronthemarket,orcostseveraltimesthepriceofcarbonblack.58Avoidingtheuseofthecolourblackinplasticpackagingproducts,ifitisnotrequiredforitsphysicalproperties,isthebestwayforwarduntilalternativesareeasilyobtainable.Thelesscolourthatisused,thelighterthecolours,andthebetteritisfortherecyclingprocess.

4.4 AluminiumAluminiumcanbeseparatedfromthewastestreaminmanymaterialrecoveryfacilities(MRF)however,notallfacilitieshavesuchequipment.Itisespeciallydifficultiftherearesmallamountsofaluminiumpresentthatcanremaintogetherwiththeplasticsandcauseproblems.Smallaluminiumparticlesintherecyclatecanalterwiththepropertiesoftherecycledmaterial.Aluminiumclosuresystemsshouldthereforebeavoidedinplasticpackaging.Allkindofmulti-materialpackagingwithaluminiumshouldalsobeavoided.

4.5 PaperPaperisthemostcommonmaterialforpackaginglabels.Paperhasbeenrecommendedasagoodlabelmaterial;however,papercanbedetrimentalintherecyclingprocessifnotseparatedfromthepackagingmaterial.Thewashingprocesswillnotremoveallpaperparticlesfromtheplasticswastestream,soremainingparticleswillcauseacontamination.Papercanalternatethepropertiesoftheplasticrecyclate,andcanalsogivetherecyclateamalodour,reducingtherecyclatesusageareas.59

4.6 PVCPVCisamaterialwithoutstandingmechanicalproperties,makingitindispensableinmanysectors.PVCiswidespreadandisthethirdmostusedplasticafterPPandPE.60PVCusedtobeheavilyusedforpackagingfoodproducts,buthasbeenphasedout.

SmallamountsofPVCmixedwithotherpolymerscanharmrecycling.TheacceptablelevelofPVCinPETforinstanceisonly0.25%.61PVCshouldthusbeavoidedasapackagingmaterial,oratleastmakeiteasilyseparatedifused.62

4.7 Adhesives

SUMMARY–ADHESIVESAdhesivesareusedonplasticpackagingtoattachlabelsandotherpackagingcomponents.Theyarealsousedforclosuresystems.Itisimportantthatadhesivescanberemovedinnormalwashingprocessestoavoidareductioninthequalityoftherecycledmaterial.Thereshouldalsobefocusonchoosingadhesivesthatdonotleaveglueresiduesontheattachedlabelorcomponentafterthewashingprocess.Itisrecommendedtochooseadhesivesthatarewatersolubleat60°C.

57OliverLambertz,Tomra58Commentfromparticipantatworkshop59MartinaLehmann,MAKSC60K-online(2016).PlentyofPotentialforRecycling.PressRelease.Availableat:http://www.k-online.com/cgi-bin/md_k/lib/all/lob/return_download.cgi/FA02_Recycling_long_version_Logo_en.pdf?ticket=g_u_e_s_t&bid=3186&no_mime_type=061PetcoreEurope(2014).RecycledProducts.Availableat:http://www.petcore-europe.org/recycled-products62Walmart(2016).SustainabilityPackagingPlaybook.Aguidebookforsupplierstoimprovepackagingsustainability.Presentation.


Theuseofadhesivesinplasticpackaginghasbeenwidelyusedovertheyearsinvaryingconcentrationsandamounts.Thereisagreementamongmanysourcesthattheuseofadhesivesshouldbereducedtoaminimuminordertopreventcontaminationoftherecyclate.Physicalcontaminationatamicroscopiclevelfromadhesivesisdifficulttoremove.Suchimpuritiescreateweakspotsandleadtoproblemsinthereprocessingofmaterials.63

Glueusedtobedifficulttoremoveandwereoftenhazardous.Someglueshadmeltingtemperaturesof170°Candcausedtroubleintherecyclingfacilitiesbecausetheycouldnotbewashedoff.64Theprocessforremovingadhesivestodayislesscomplicatedasthereareseveralrestrictionsonwhichadhesivesthatareacceptableforuse.Dependingonthetemperaturesused,adhesivescanbedissolvedbyusingchemicalfiltrationorparticlefilters–processesthatarenotfurtherelaboratedindepthinthisguide.Thetreatmentprocessheavilyinfluencestherecyclingprocessandthequalityoftheendproduct.65

Thereisagreementamongstexpertsthatadhesivesshouldbewateroralkalisolubleatlessthan80°C,however,severalsourcesstatethatthemaximumtemperaturenecessaryshouldbelimitedto60°Ctoreduceenergyuse.Othersourcesstatethatwater-solubleadhesivesaretheonlyoptionandalkali-solubleonesshouldbereduced.66Thereisagreementthatadhesivesthatarenotsolubleinwateroralkaliconditionsabove80°Cshouldbeavoided.

ADHESIVES Non-adhesive Water/alkalisoluble<60°C Water/alkalisoluble60-80°C Nonwater/alkalisoluble>80°CHDPE Yes Yes Notideal NoPET Yes Yes Notideal NoPP Yes Yes Notideal NoLDPE Yes Yes Notideal NoPS Yes Yes Notideal NoTable3–Compatibleadhesivesforplasticpackagingofdifferentmaterialtypes.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

4.8 InksandPrinting

SUMMARY–INKSANDPRINTINGPrintinginformation,usingink,directlyontothesurfaceofthepackagingproductshouldgenerallybeavoided.Thiswillcontributenegativelyintherecyclingprocessandforthequalityoftherecyclate.‘Bestbefore-dates’canbeprintedonthepackagingproduct,however,preferablyitshouldbeprintedontothelabelorsleeve.LaserprintingisanacceptablesolutionforPET,HDPE,andrigidPPpackagingproducts.

MostexistingguidelinesrecommendtheminimumprintingrequirementsthatfollowexistingEuropeanregulationsandindustrystandards.67Theyrecommendthatthedateofproductionand/orexpiryistheonlythingthatshouldbeprintedonapackagingproduct.Thereasonforthisisthatinkscauseabig

63PetcoreEurope(2014).RecycledProducts.Availableat:http://www.petcore-europe.org/recycled-products64MartinaLehmann,MAKSC65MartinaLehmann,MAKSC66Walmart(2016).SustainabilityPackagingPlaybook.Aguidebookforsupplierstoimprovepackagingsustainability.Presentation.67EuropeanPrintingInkAssociation(EUPiA)


problemforthewatertreatment.68Inksthatbleedintherecoverystreamwashwatercancontaminatethewaterandtherecyclate.

Water-basedprimersaretheeasiesttoremoveusingprintingorinkremovaltechnology.Alkalinesolutionscanbeusedtoremoveinks.69Itistechnicallyfeasibletoremoveinksfromsometypesofflexiblepackaging;however,ithasnotbeeneconomicallyviableforpost-consumerhouseholdfilms.70Thecostsinvolvedintheremovalofinks,exceedthefinancialbenefitofproducingcolourlessorlightcolouredrecycledmaterial.71

Inmanyrecyclingprocesses,theinkisnotremovedandthefinalrecycledpolymerhasagreyish-greencolour.Thecoloursdonotinfluencethephysicalpropertiesofthematerialbutitcanlimittheapplicationstherecycledplasticcanbeusedforintheendmarket.

LasermarkedprintingisacceptableforrigidPPproducts,butnotPP-film.Minimalprintingofthedateofproduction/expiryonPETpackagingisacceptable,howeverlasermarkedprintingisabetteroption.

PRINTING Lasermarked Minimalprinting(dateofproduction/expiry) AnyotherdirectprintingHDPE Yes Yes NoPET Yes Conditional NoPP Conditional Yes NoLDPE Yes NoPS Yes No

Table4-Compatibleprintingoptionsforplasticpackagingofdifferentmaterialtypes.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

4.9 Sleevesandlabels

SUMMARY–SLEEVESANDLABELSItisimportanttochoosetherightlabelandsleevematerialbasedonhowitwillaffectthesortingandrecyclingprocess.Sleevesandlabels,notremovedbyconsumers,areinmostcasesnotrecycled.Thus,itismoreimportanttochooseasolutionthatcaneasilybeseparatedfromthepackagingproductintherecyclingprocess.SeparationhappensinawaterstagewherePEandPPcanbeseparatedfrompackagingproductsthathaveadensityofmorethan1g/ccm.Filmcanbeseparatedfromthick,rigidpackagingbyusingahydrocyclone/sentrifugebeforethedryingprocess.Ageneralruleisthatsleevesandlabelsshouldnotcovermorethan60%ofthepackagingsurfacethatisscannedbytheNIRdetector.Thisisessentialtosecurelyidentifytheproductandensureahighhit-rate.Ifthesamematerialischosenforthesleeve/labelandthepackagingproduct,onecandeviatefromthisrule.

68MartinaLehmann,MAKSC,11,Walmart69Commentfromparticipantatworkshop70McKinlay,R.andMorrish,L.(2016).REFLEXProject–ASummaryReportontheResultsandFindingsfromtheREFLEXProject.AxionConsulting.71McKinlay,R.andMorrish,L.(2016).REFLEXProject–ASummaryReportontheResultsandFindingsfromtheREFLEXProject.AxionConsulting.


Basedonseveralrecommendations,thesleeveandlabelshouldnotcovermorethan60%ofthesurfaceofapackagingproduct.Ifthelabelcoverstoomuchofthesurface,theNIRdetectorintheMRFwillhavetroubleidentifyingthepackagingmaterialandmaynotbeabletosorttheproductintoitscorrectmaterialfraction.72ThelabelareashouldbeminimisedtoavoidissueswiththeNIRtechnologyandtoavoidrejectionfromthehighvaluerecyclestream.73Ifitispossibletoavoidtheuseofasleeveorlabel,thenthatisideal,howeverthisdependsonthealternative.TherearemostlikelyvariationsinNIRtechnology,andwhatresolutionthemachineusestoreadthematerial.

Labelsandsleevesareremovedintwotypesofprocesses,dependingontherecyclingfacilityandwhichprocesstheywanttouseeitherawetcleaningprocessusingchemicals,oradryprocessusingfriction(orboth).74Makingthelabelorsleeveeasytoremoveisalsoanimportantfactorformakingthemseparablefromtheproductbody.75Thesleeveorlabelshouldideallyseparatefromthepackagingbodyinthewashingprocess.76Sleevesandlabelsthatarenotremovedbyfrictionwashingareremovedatalaterstagewherethematerialsareseparatedinaconventionaldensityseparationprocessorbytheuseofawindturbine.Forthisreason,sleevesandlabelsthathaveadensityofmorethan1g/ccmaredeemedunsuitable;becauseitismoredifficulttoremovethem.However,thisdependsonthematerialofthesleeveandtheproduct.77Fullsleevelabelsarerelativelyheavyandcanaffectbaleyieldsorthematerialsenttorecycling.78Itshouldbepossibletoseparatesleeves/labelsfromplasticpackagingproductsthroughafloat/sinksystem.79

ItisvitalthatthesleeveisconstructedandconfiguredsothattheautomaticsortingbytheNIRdetectorcancorrectlyidentifythematerialofthepackagingproduct.80Dependingonthethicknessofthesleeveorlabel,theNIRdetectorwillreadmoreorlessinformationfromthelabelmaterial.Itcanbedifficulttoknowwhetherthemachinewillreadthepackagingmaterialorthesleeve/label.81Itisthereforeimpossibletogivearecommendationonsleeveandlabelthickness.

ThereisuncertaintyastowhetherthecolourofasleeveorlabelwillaffectthedetectionoftheplasticpackagingmaterialintheNIRdetectorandultimatelyaffectwhethertheproductissortedintothecorrectfractionornot.Thereisagreementamongstsourcesthataslongasthesleeveorlabeldoesnotcovermorethan60%ofthesurfaceoftheproduct,thecolourshouldnotaffecttheprocesssignificantly.

Therearemanydifferentrecommendationsgivenastowhatmaterialthesleeveorlabelonaproductshouldhave.Thiswillmostlydependonthematerialofthemainpackagingbody.Inthesortingprocess,itiseasieriftheproducthasthesamematerialasthesleeveorlabel,asitismorelikelytobesortedintotherightmaterialfraction.However,inthewashingprocessitiseasiertoseparatethetwofromeachotheriftheyaremadefromdifferentmaterials.82

72AssociationofPostconsumerPlasticRecyclers(2016).SelectingShrinkSleeveLabelsforPETPackaging–anAPRDesignGuideBulletin.Availableat:http://www.plasticsrecycling.org/images/pdf/design-guide/Technical-Bulletins/APR_PET_Sleeves_Tech_Bulletin.pdf73AssociationofPostconsumerPlasticRecyclers(2016).SelectingShrinkSleeveLabelsforPETPackaging–anAPRDesignGuideBulletin.Availableat:http://www.plasticsrecycling.org/images/pdf/design-guide/Technical-Bulletins/APR_PET_Sleeves_Tech_Bulletin.pdf74MartinaLehmann,MAKSC,Karen,Kidv75ThomasEtien,Danone76AssociationofPostconsumerPlasticRecyclers(2012).PrinciplesforSleeveLabelsonPETBottles.Availableat:http://www.plasticsrecycling.org/images/pdf/PET-Resins/PET-Bottles/principles_for_sleeve_labels_on_pet_bottles.pdf77K-online(2016).PlentyofPotentialforRecycling.PressRelease.Availableat:http://www.k-online.com/cgi-bin/md_k/lib/all/lob/return_download.cgi/FA02_Recycling_long_version_Logo_en.pdf?ticket=g_u_e_s_t&bid=3186&no_mime_type=078AssociationofPostconsumerPlasticRecyclers(2016).SelectingShrinkSleeveLabelsforPETPackaging–anAPRDesignGuideBulletin.Availableat:http://www.plasticsrecycling.org/images/pdf/design-guide/Technical-Bulletins/APR_PET_Sleeves_Tech_Bulletin.pdf79AntonioFurfari,PlasticsRecyclers80AssociationofPostconsumerPlasticRecyclers(2012).PrinciplesforSleeveLabelsonPETBottles.Availableat:http://www.plasticsrecycling.org/images/pdf/PET-Resins/PET-Bottles/principles_for_sleeve_labels_on_pet_bottles.pdf81OliverLambertz,Tomra82OliverLambertz,Tomra


4.10 ResiduesItisnormaltofindproductresidualsontheplasticpackagingafteruse.Itisnotunusualtofind15-20gofproductleftineverybottle–alargeamount.83Thepackagingmustbeeasytoemptyfortheconsumer.

Ifapackhasproductin,itmaynotpassthroughthesortingsystemscorrectly,duetoexcessweight.Ifitpasses,itisimportanttostressthatthewashingprocesswillnotremovealltheresidues,soanydangerouschemicalsremaininginthepackagingcouldbedisastrousiftheyenterthewastestream.Chemicalcontaminationisnotuncommonandoccursbytheadsorptionofflavourings,essentialoils,etc.thatthepackagingcontains,orduetoacontainerbeingre-usedforpurposesotherthantheoriginalone.84Ifthepackagingcontainsresidues,itshallbetreatedas(dangerous)waste.

Residuesinthewastestreamcanultimatelygivetherecycledmaterialanodour.Ifthereareproblemswithodourintherecyclate,therecycledplasticislesssoughtafter.Completeremovalofresiduesinthewashingprocessrequires“desorption”,aslow,time-consumingprocess,decreasingproductivity.85Thepackagingmustthereforebeeasytoempty,whetheritisatray,bottle,cuporotherformofpackaging.

4.11 Biobased,Oxo-Degradable,andBiodegradablePlastic

SUMMARY–BIOBASED,OXO-DEGRADABLE,ANDBIODEGRADABLEPLASTICBiobased,renewableplasticsareplasticsproducedfromrenewablematerialthathaveasimilarpolymerstructureandphysicalpropertiestothoseplasticsproducedfromfossilfuels.Biobasedplasticsarenotbiodegradable,buttheyarecompatibleintherecyclingprocess.GreenPEisanexampleofabiobasedplastic,andhasbeenfoundtohavethesamerecyclabilityasfossil-PEandcangenerallyberecommendedintermsofitsabilitytoberecycled.Biobasedplasticsconstituteca.80%(5milliontons)oftheworld’stotalproductioncapacityforbiobasedplasticsandbiodegradableplasticsin2017.Theamountoftheestimatedproductioncapacitythatisusedisunknown.Biodegradableplasticsconstitutescompostable,biodegradable,andoxo-degradableplasticswherethereisarangeofvarietiesthatarebothbiobasedandfossilbased.Thesematerialsaregenerallyincompatiblewithnon-biodegradablepolymermaterialsintheproductionofnewrawmaterials.Thistypeofplasticisnotsuitableforrecyclingandcanpotentiallyreducethepotentialsforhighvaluerecyclingoffossil-basedplasticsiftheyareaddedtotheconventionalplasticsrecyclingstream.Evenasmallinfluxofthesecandamagetherecyclingofconventionalplastics.BiodegradableplasticswillnotnecessarilybeidentifiedbytheNIRdetectorintheMRF,andwillthereforelargelyendupinthegeneralwastefractionorthemixedplasticsfraction.However,asmallamountofcontaminantsinthedifferentplasticfractionsisunavoidable,andsomeofthiscouldbebiodegradablefractions.ThechallengeintheMRFisexceptionallylargeforbiodegradableplasticsthatarebasedonnormalpolymersandareidentifiedassuchbytheNIRdetectors.Oxo-degradablePEisanexampleofthis.Biodegradableplasticswillthencontaminatetheproductstream.Inthesubsequentwashingandseparationprocesses,biodegradableplasticscanberemovediftheyhaveadifferentdensitythanthefossilproductstream(over1g/ccmforPOorunder1g/ccmforothertypes).Thisishowevernotthecaseforoxo-degradablePE.

83Commentfromparticipantatworkshop84PetcoreEurope(2014).RecycledProducts.Availableat:http://www.petcore-europe.org/recycled-products85PetcoreEurope(2014).RecycledProducts.Availableat:http://www.petcore-europe.org/recycled-products


Eitherway,itisimpossibletoavoidasmallinfluxofcontaminantsintherecyclate.Biodegradableplasticsrepresentacontaminantinthesortingandrecyclingprocessofconventionalplastics.Theuseofbiodegradableplasticsisthereforenotrecommended.Biodegradableplasticsaredifficulttoremovefromtheconventionalplasticsstreamandwillhaveanegativeimpacteveninsmallamounts.Especiallybiodegradableplasticsthatareoftenidentifiedaspolyethylene(PE)orotherplasticsthataresortedout,willcreateproblems.Thesecontaminantswillimpactthepropertiesoftherecyclateanditsapplicationareasinanegativedirection.Increasinguseofbiodegradableplasticsisthereforeathreattotherecyclingofconventionalplastics.Biodegradableplasticscanalsocreatechallengesinthecollectionandrecyclingoffoodwaste.Biodegradableplasticsandallotherplasticsarenotwantedinbiogasplants.

Fulltextforbiobasedanddegradableplasticisinattachment7.4.


5. PackagingFilm

SUMMARY–FILMSwedenandNorwayhaveahighconsumptionrateofLDPEfilmusedforconsumerpackagingthatissuitableforrecycling.PPfilmisalsowidelyusedbutthismaterialtypedoesnothavethesamerecyclingpotentialbecauseamarketforthistypeofrecyclatehasnotyetbeendeveloped.Thereisasignificantshareoffilmproductsthatarecomposedofvariousmaterialstocreatedifferentbarriers,suchasforoxygenorwater.LDPElaminatedplasticscanbedifficulttoseparatefrompureLDPEfilmintheNIRdetectorandthisisthereforeachallengeforrecyclers.ByadjustingtheNIRequipmenttheshareoflaminatedplasticsinthepurefractioncanbereduced,howeverthedividendofpureLDPEwillalsodecrease.Aprocessformakingbarriermaterialsmoreacceptableintherecyclingprocessisunderway,especiallyforEVOH.VariationsofPE/PAandPE/PETisnotrecommended.ItisnormaltofindasmallamountofPPfilmintheLDPErecyclate.Afractionof3%canbeaccepted.Biodegradablefilmthatisnotseparatedinthesortingprocessisnotwanted.Itisespeciallydifficulttoseparateoxo-degradablePEfromtheotherfractions.

5.1 FilmapplicationsFilmisusedforavastnumberofapplicationsrequiringavarietyofproperties,includingfilmformeatpackaging,differentpouchesforsnacksetc.,shoppingbagsandastransportpackaging.

Basedontheneededproperties,filmcanbemonolayerLDPE,multilayerLDPE,multilayerwithbarriermaterialsormonolayerPPorothermaterials.LDPEisbyfar,stillthemostcommonmaterial.

Forrecycling,LDPEistheonlytargetedmaterial.Allothermaterials,likePP,biodegradablefilm,laminatesetc.areregardedasacontamination.However,householdwastecollectionmaycompriseofalltypesofplasticpackaging.ThismeansthattheMRFsmustsortoutacleanLDPEfractionforrecycling,whileallotherfilmsaresortedoutforincineration.Inpractice,about85%ofalltheseotherfilmsaresortedout,while15%endupintheLDPEfractionascontamination.Someofthesecontaminationscanberemovedduringthewashingprocesses.Thegivenpercentagescanvarybasedonadjustmentsofsortingmachines;TheLDPEfractioncanthusbeevencleaner;however,suchadjustmentsresultinincreasedlossesalsoofLDPEintheprocess.

LDPEfilmthatisseparatedfromotherhouseholdpackagingwillbeamixofcolours,thicknessesandqualities.High-graderecyclingoffilm-productsfromhouseholdsinvolvescreatingnewfilm-products.Therearealsootherproductswithsomewhatlowerqualityrequirements.

TheendmarketforrecycledLDPEfilmvariesdependingonthematerialanditsquality.Measurestoimprovetherecyclingprocessincludepackagingdesign,forexamplemakinggoodchoiceswhenusinglaminatedLDPEpackagingforaproduct.

5.2 LabelsLabelsthataremadeofthesamematerialasthepackagingbody,oracompatiblematerial,isthepreferredoption,asthiswillnotcontaminatetherecycledfilm.LDPEandPPlabelsarethereforepreferred.

PETlabelscanbeseparatedfromLDPEandPPfilminasink/floatprocess;however,itcanbedetrimentalifalargefractionremainsintherecyclate.Itisthereforebettertoavoidtheuseofthismaterial.


Paperlabelscausetroubleintherecyclingprocessiftheyarenotseparatedbyseparationsystemsinwashingprocesses.Theycausecontaminationoftherecyclateandcanleadtomalodouroftherecycledmaterial.

Ifthepaperlabelsaresatisfactoryremovedfromthepackagingbyusingawindshift,thenthepotentialhazardpaperhasisheavilyminimised.86

IDEAL GOOD NOTIDEAL BADNone LDPE

PP/OPPPETPaper

MetalPVC

Table5-Compatiblematerialtypesforlabelsonfilmpackagingproducts.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

5.3 AdditivesandBarriersLDPE-filmandPP-filmofferlimited,tonobarrierpropertiesontheirownandthereforeoftencontainadditivestogivethefilmitsnecessaryproperties.Whenthepackagingfilmconsistsofseverallayers,itiscalledalaminatedplastic.Laminatedplasticscanbecreatedintwoseparateways,eitherbygluingseparatelayersthatdonothavecompatiblemeltingtemperaturestogether,orbyco-extrudingtheminonesingleprocess.

LDPE-filmandPP-filmthatcontainbarriermaterialsarechallengingtobothsortandrecycle.AfractionofthesewillnotbeabletobesortedoutbytheNIRdetector,andwillremaintogetherwiththefilm-fractiontotherecyclingfacility.Coatingsandlayersarenotremovedinthefilmrecyclingprocess,butareeithermeltedorblendedtogetherwiththematerial.Theeffectthatthesecoatingsandlayershaveontherecyclateisuncertainandthereforerequiresfurthertesting.AreductionintheamountoflayersinLDPEfilmisadvised–fewerlayerswillleadtolesscontaminationintherecyclatematerialstreams.87Non-PElayersinfilmcouldharmtherecyclate,sotheircontentshouldbeminimised.88

EVOHisthemostcommonbarriermaterialforLDPE.EVOHiseasiertocombinewithpolyolefins,LDPEandPP,thanPA.PAshouldnotbecombinedwithEVOHandLDPE.89Iftheproducthasashelflife,itrequiresthebestpossiblecombinationofmaterials.ThereismoreandmoreevidencethatPAisreducinginuse.90

Cautionshouldbeexecutedwhencombiningfillerswithfilmasthiscouldaltertheoveralldensity.Asdensityisacriticalseparationtool,thefilmshouldfloat,ratherthansink.91

IDEAL GOOD NOTIDEAL BADNone EVOH(<2%oftotal

weight)PETPA(<1%oftotalpackweight)EVOH(<10%oftotalpackweight)PET

AluminiumMetallizedPA(>1%oftotalpackweight)EVOH(>10%oftotalpackweight)

86AssociationofPostconsumerPlasticRecyclers(2013).APRDesignforRecyclabilityGuidelinesforLDPE,LLDPE,HDPEFilm.Availableat:http://www.plasticsrecycling.org/images/pdf/design-guide/PE_Film_APR_Design_Guide.pdf87Commentfromparticipantatworkshop88AssociationofPostconsumerPlasticRecyclers(2013).APRDesignforRecyclabilityGuidelinesforLDPE,LLDPE,HDPEFilm.Availableat:http://www.plasticsrecycling.org/images/pdf/design-guide/PE_Film_APR_Design_Guide.pdf89MartinaLehmann,MAKSC90Commentfromparticipantatworkshop91AssociationofPostconsumerPlasticRecyclers(2013).APRDesignforRecyclabilityGuidelinesforLDPE,LLDPE,HDPEFilm.Availableat:http://www.plasticsrecycling.org/images/pdf/design-guide/PE_Film_APR_Design_Guide.pdf


PVC,PVdCTable6-Compatibleadditivesandbarriermaterialsforfilmpackagingproducts.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

5.4 SortingandRecyclingThereisgenerallyalotofcontaminationinthefilm-fractionatarecyclingfacility.Filmisdifficulttorecyclebecausetherearesomanydifferenttypeswithvariousmeltingpoint,barriersandadditives,dependingonthepropertiesrequiredofthematerial.Althoughthemarketforrecycledfilmisminor,itisimportanttosecurelargevolumesofthis,andthatthisfractioniskeptatahighquality.

5.4.1 PP-filmPP-filmcanberecycledinprinciple,butbasedonitslimiteduse,demandforhighquality,andthenon-developedmarketforrecycledPPfilm,recyclingofthismaterialisstillnoteconomicallyviable.ThecollectedvolumeofPPfilmisverysmallandtherearethereforefewwhorecycleittoday.92

Duringthesortingprocess,PPfilmcanintheory,beseparated.However,PPfilmandallothernon-LDPEfilmsareinpracticesortedoutforincineration.Asanalternative,somePP-filmareacceptedinamixedPOfractionforrecycling.

IfPP-filmshallbesortedoutasasinglestream,thechallengeistopreventrigidPPfrombeingsortedintothePPfilmfraction.SomerigidPPproductsareoftenidentifiedastwo-dimensional,lidsarecommon,andaresortedtogetherwiththefilmfraction.93

B-OPPorOPParemonomaterialswithadditionalbarrierfunctionsarisingfromtheproductionofthematerialwherethemoleculestructurehasbeenchangedbyphysicalstretching.94ItisunsurewhetherthispropertyposesanaddedchallengeintherecyclingfacilityforPP-filmrecycling.SomePPmaterial,incl.B-OPP,isrecyclable,forexampleaspartofamixedPO.However,itlosesitsorientation-qualityintheprocess.Theywillbedowngradedandusedforotherpurposes.95CertainB-OPPorOPPproductsareverydelicatewherealonglifetimeandtheabilitytotoleratehighpressuresmustbeguaranteed.Recycledmaterialcanthereforenotbeusedintheseproducts.

PP-filmcantoacertainextentberecycledasapartoftheHDPE/PPfraction.96PPfilmcontaminatestheLDPEfractionifitismixed.ThePPfractioncanbeheavilycontaminatedifPETismixedintoit.

CurrentPPfilmsrequireaveryhighqualitythatisdifficulttoachievewithcurrentrecyclingsystems.ItispossibletorecyclePPandreachasimilarquality,butthisispioneerwork.

5.4.2 LDPEfilm70-80%ofthematerialthatcomesoutofalargeMRFinNorwayisLDPE.Itisahugefraction.Monolayerfilmsaresortedtoday,butnotmuchelse.97LDPEoffersnootherbarrierotherthanahumiditybarrier.Forthisreason,LDPEfilmoftenhasadditives.ThebarrierlayersinPEfilmsarewhatcausesproblemswith

92OliverLambertz,Tomra,Commentfromparticipantatworkshop93OliverLambertz,Tomra94KarenvandeStadt,Kidv95AntoninoFurfari,PlasticsRecycling96MTM,somefilmacceptedaspartofPOfraction97ThomasEtien,Danone


recycling.However,ifthebarriersareremoved,thenprotectionoftheproductisgone.Iftheselayerscanbereducedwithout,compromisingthequality,thenthatwouldbeideal.98

LDPEisrecycledincombinationwithPA.TherehavebeenattemptstoseparateLDPEfromPAintherecyclingprocess,butthereisnoconcreteevidencethatthisispossible.Thedivisionprocessmayhavetoincludeseveralsteps.LDPEwithPAisdifficulttorecyclebecausethematerialshavedifferentmeltingpoints.LDPEandPAarenotsocompatiblesoadhesivesarerequiredtobindthematerialstogether.99

PETintheLDPEfractionisaproblemforrecycling.A3%fractionofPPintheLDPErecyclateisacceptable.100Ifthereismorethan2%biodegradablematerialintheLDPEfraction,itwillcauseproblems.101

TherearemovementstoreplacePPfilmwithPEfilmbecauserecyclingsystemsexistforLDPE,andnotforPP.Nevertheless,inordertoprovidethesamefunctionalityandproductprotection,PEfilmsmayneedtobethicker,andarehencelessresourceefficient.102

98Commentfromparticipantatworkshop99Commentfromparticipantatworkshop,MartinaLehmann,MAKSC100MartinaLehmann,MAKSC101MartinaLehmann,MAKSC102NinaAckermans,Borealis


6 RigidandThermoformedPackaging

6.1Polypropylene(PP)products

SUMMARY–PPPPisusedforawiderangeofapplications,amongstthembottles,trays,boxes,cups,lidsetc.ThereisanendmarketfordifferenttypesofrecycledPPinvariouscoloursthatworkswell.However,thismarketcanbefurtherdevelopedtoensureahigherqualityrecyclategivesawiderrangeofapplications.Itisrecommendedthatlids,caps,sleevesandlabelsonPPproductsbemadefromthesamematerial,thatincludesOPP.HDPEorLDPEarealsoacceptablematerialsonPPpackaging,astheywillnotheavilyaffectthequalityoftherecycledendproductinmostcases.CombinationsofPP/PETshouldbeavoided,eventhoughthematerialscaninsomeplacesbeseparated.TherearenogoodsolutionsfortheuseofbarriermaterialsinPPproducts.Ifgoodbarrierpropertiesarerequired,otherpackagingmaterialsarelikelytobebetter.PPpackagingcanideallybesortedbycolourasdarkcoloursaregenerallylesswelcomeandhavealowervalueontheendmarket.Useofthepigmentcarbonblackisnotrecommended.

6.1.1. PPapplicationsTherangeofPPapplicationsisverylarge,givingrecycledPPahigh-endmarketvalue.103PPistypicallyfoundinyoghurtcontainers,ketchupbottles,syrupbottlesandmedicinebottles.104Itisagoodmaterialforstoringacids,basesandothersolvents.Itisastrongmaterialwithahighmeltingpoint.

TheoutletsofrecycledPPareoftencrates,bottles,andotheressential‘lowvalue’productssuchasbrooms,autobatterycases,bins,pallets,signallights,icescrapersandbicycleracks.105Theseareoftenwhiteorcolouredandareusuallythick-walled.106

6.1.2. ColoursTherearemanycompatiblecoloursforPPpackagingproducts.Allcolours,exceptforcarbonblack,havethepotentialtoberecycled;however,thereisnotalwaysamarketforit.107RecycledPPhasahighvalueasthequalityisgood,andcanbeusedformanydifferentapplications;fromdishbrushesandotherkitchenutensilstoparkbenchesandcrates.

AlthoughmosttypesofPPinvariouscolourscanberecycled,thequalityoftherecycledproductwillvarydependingontheamountofdifferentcoloursinaproduct.Thepackagingproductwillhavealesservalueiftherearemanycoloursmixedinthepackaging.Thepackagingshouldideallyconsistofasfewcoloursaspossible.

103MartinaLehmann,MAKSC104NaturalSociety(201).TheNumbersonPlasticBottles:WhatdotheRecyclingSymbolsMean?Website.Availableat:http://naturalsociety.com/recycling-symbols-numbers-plastic-bottles-meaning/105NaturalSociety(201).TheNumbersonPlasticBottles:WhatdotheRecyclingSymbolsMean?Website.Availableat:http://naturalsociety.com/recycling-symbols-numbers-plastic-bottles-meaning/106KarenvandeStadt,Kidv107OliverLambertz,Tomra


ThemixingofcoloursinPPpackagingproductsshouldunderidealconditionbeavoidedinordertoproducedistinctstreamsofdifferentcoloursofrecycledPP,increasingtheamountofapplicationsitcanbeavailableforontheendmarket.

CarbonblackisnotanidealcolourforPPpackaging,astheNIRdetectorcannotbedetectedintheMRF.ThereisanewPPproductunderdevelopmentthatdoesnotcontaincarbonblack,blackPPtrays.ThistrayhasbeentestedinNorwayandcouldbedetectedbytheNIRdetectorattheRoAfMRF.108

6.1.3. ClosureSystemsWhenusingclosuresystemsonPPpackaging,itisanadvantagethattheyarethesamecolourasthebottle.Thisisnotessential;however,ithelpsreducecolourcontaminationintherecycledproduct,givingitbetterqualityandahighervalueontheendmarket.

PPcaps,orOPP,areidealforPPbottlesastheycanberecycledtogetheranddonotrequireseparation.OPPisamonomaterialwithadditionalbarrierfunctionsduetoaphysicalstretchingofthemolecularstructure.Thiswillnotcreateproblemsintherecyclingprocess.109CapsmadeoutofHDPEarealsogoodforPPpackagingproducts.HDPEandPParebothpolyolefinsandthereforehavemanyofthesameproperties.HDPEhasalowermeltingpointthanPP(ca.130°Cvs.170°C),andasmallamountofHDPEinthePPfractionwillnothavedetrimentalconsequences.110

IfPETismixedupintotherecycledstreamofPP,itcancausecontaminationoftherecycledproduct.PETisthereforenotanidealmaterialtocombinewithPP.EveniftheproductgoesthroughaMRFtoseparatethetwomaterialsfromoneanother,therewillalwaysbeasmallfractionthatwillnotbesortedout.Ifalessidealmaterialischosen,itisimportantthatthedensityisabove1.0g/ccmsoitcaneasilybeseparatedfromthepackaginginconventionaldensityseparationprocesses.

Aluminiumisacommonmaterialusedforcreatingasealunderplasticlidsinproductslikebuttertubs.Aluminiumisgenerallynotacceptableunlessitcan,andwill,becompletelyremovedbytheconsumerandwillnotendupintheplasticsfraction.

IDEAL GOOD NOTIDEAL BADPP,OPP

HDPELDPELLDPE

PET

PSPVCThermosetplasticsSiliconeMetals

Table7-CompatibleclosuresystemsforPPproducts.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

6.1.4. SleevesandlabelsAsfortheclosuresystem,itisanadvantageinthePPfractionthatthesleevesandlabelsareofsimilarcolourstothemainpackagingbody.AsmuchofthePPcanberecycled,maincolourPPstreamsaredesiredtoreachthehighestqualityoftherecycledproduct.

PEandPParegoodmaterialsforsleevesorlabelsonaPPpackagingproduct.111PEandPPhaveverysimilardensitiesanditisthereforedifficulttoseparatethem.However,asmentionedabove,PEandPP

108OliverLambertz,Tomra109KarenvandeStadt,Kidv110RECOUP(2016).PlasticPackaging.RecyclabilitybyDesign.TheEssentialGuideforallthoseInvolvedintheDevelopmentandDesignofPlasticPackaging.http://www.recoup.org/p/130/recyclability-by-design111MartinaLehmann,MAKSC


arebothpolyolefinsandPEcausesthereforelittleharmintherecycledfraction.PEhasalowermeltingtemperaturethanPPandcanthereforebeprocessedtogetherintootherhigh-gradeproducts.112SmallfractionsofPEcanhencebeacceptedinthePPfraction.

PETisnotanidealmaterialforasleeveorlabelonaPPproductbecausePETcanhighlycontaminatetherecycledPPfraction.However,aPETsleeveonaPPbottleispossiblebecausethedensitiesaredifferentsotheycanbeseparatedinaMRF.Nevertheless,becausetheMRFcanneversortout100%ofthesleevesandlabels,PETislikelytobemixedintotherecycledPP.PETisthereforeacceptableinsmallquantities;however,itshouldpreferablybeavoided.PShasasimilarstorywhereitisonlyacceptableinsmallquantitiesasitcancontaminatetherecycledPP.

WhencomparinglabelsandsleevesonaPPbottle,toprintingonPP,sleevesandlabelsarebetterforgivingPPahighvalueattheendmarket.Inksaredifficulttoremoveandendupcontaminatingtherecycledflakes,whichlowersthevalueandcausesabadsmell.Aspecialextrusionisneededinordertoremoveinks,whichisanexpensiveandtechnicallydifficultprocess.Thistypeofcontaminationcausesproblemsintherecycledfraction,whichrequirestheuseofmoreadditives.LosingsleevesandlabelstoincinerationispreferredinordertoachieveahighqualityoftherecycledPP.113

In-mouldlabellingiscommonforPPpackagingproductsanditisgoodforsortingandrecycling.However,thisisexpensiveandcouldcausechallengesintherecyclingprocessdependingonhowmuchcolourhasbeenusedforthein-mouldlabel.114

Ifalessidealmaterialischosen,itisimportantthatthedensityisabove1g/ccmsoitcaneasilybeseparatedfromthepackaginginconventionaldensityseparationprocesses.

IDEAL GOOD NOTIDEAL BADLDPEPP

Removablein-mouldlabelOPP

PaperPETPS

MetalPVC

Table8–CompatiblesleeveandlabelmaterialsforPPproducts.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

6.1.5. AdditivesandBarriersPPhaslowbarrierpropertiesandisthereforemostlyusedinpackagingthatdoesnotrequireaspecificoxygenbarrier.InorderforPPtoachievethesamebarrierpropertiesasPET,itwouldrequireaverythicklayerbetweentwothicklayersofPE.115

EVOHisacommonbarrieraddedtoPPtoincreaseitsbarrierproperties.EVOHisacceptedinthePPrecyclate,inadditiontoPA-basedbarrierlayers;however,theiruseshouldbeminimisedastheycontaminatetherecycledPPfraction.EVOHcausesbubblysurfacesoftherecyclate.116ItisnoteworthythatPPwithEVOHisnotasbadasPETwithEVOH.117

Byaddingfillersand/orbarrierstoPP,thedensityofthepackagingmaterialwillincrease.IfthedensityofPPincreasestoabove0.995g/ccm,itwillbedifficulttoseparatePPfromotherplasticmaterialsintheconventionaldensityseparationprocessesattheMRF.Theamountoffillersand/oradditivesinPPis

112K-online(2016).PlentyofPotentialforRecycling.PressRelease.Availableat:http://www.k-online.com/cgi-bin/md_k/lib/all/lob/return_download.cgi/FA02_Recycling_long_version_Logo_en.pdf?ticket=g_u_e_s_t&bid=3186&no_mime_type=0113MartinaLehmann,MAKSC114MartinaLehmann,MAKSC115PaulEast,RECOUP116KarenvandeStadt,kidv117Commentfromparticipantatworkshop


thereforeveryimportant.Ifthedensityincreasestoabove1.0g/ccm,themostofthepackagingwillbelostintherecyclingprocess.118ItisforthisreasonthatEVOHandPA-basedbarriermaterialsareseparatedintheTablebelowbasedontheircontentlevelsofthetotalpackweight.

TheuseofPVdCshouldbeavoidedasitcausesdiscolourationoftherecycledPETandcanleadtomalodour.119

IDEAL GOOD NOTIDEAL BADNone None PA(<1%oftotalpack

weight)EVOH(<10%oftotalpackweight)

PA(>1%oftotalpackweight)EVOH(>10%oftotalpackweight)PVdC

Table9-CompatibleadditivesandbarriersforPPproducts.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

6.1.6. SortingandRecyclingTherecyclingofPPisratherstraightforward.120MuchofthePPfractioncantodayberecycled;however,asdiscussedinthesectionsabove,therearemanyelementsthatcouldpotentiallycausecontaminationoftherecycledfraction,givingitalowerquality.PPpackagingshouldbekepttoadensitybelow0,995g/ccminordertoseparateitfromotherplastictypesintheMRF.121

PPcanbeusedforawiderangeofapplicationsandthereforehasvalueontheendmarket.However,therecyclingmarketforPPtodayisnotveryextensive.ThisismostlybecausethecostofrecyclingPPissohigh,whichinturnmakestherecycledmaterialverycostly.

Insummary,itisacceptabletomixPPusedfordifferentapplications.122AllPPproductsareprocessedatabout220°Ctemperature,sotheycanbemeltedandreprocessedtogether.123PP-filmisadifferenttypeofPPmaterialthathassimilarpropertiedtorigidPPbutshouldbeavoidedintherigidPPfractionifpossible.Itisacceptabletohaveroughly5%PPfilmintherigidPPfraction.124

Themoremonomaterialsthatexistintherecyclate,thehigherthequalityitwillhave.IftherecycledPPcontainsothermaterials,theywillaffectthepropertiesofPP.Morethan3%PETinPPcouldbedetrimental,andmorethan5%PSisnotgoodforthePPfractioneither.125However,theamountofothermaterialsinPPisdependentontheendproduct.SomePEinthePPfractionisnotsobad,lessthan5%,butitheavilydependsonwhatendproducttherecycledPPisgoingto.126

ThereisanexistingmarketforrecycledPPinaverywiderangeofproductssuchasautomotiveapplications,buckets,capsandclosures,gardenfurniture,pallets,pipes,andmore.127

118OliverLambertz,Tomra119RECOUP(2016).PlasticPackaging.RecyclabilitybyDesign.TheEssentialGuideforallthoseInvolvedintheDevelopmentandDesignofPlasticPackaging.http://www.recoup.org/p/130/recyclability-by-design120AntoninoFurfari,PlasticsRecyclers121OliverLambertz,Tomra122MartinaLehmann,MAKSC123MartinaLehmann,MAKSC124OliverLambertz,Tomra125MartinaLehmann,MAKSC126MartinaLehmann,MAKSC127MilikenChemical


6.2. HighDensityPolyethylene(HDPE)products

SUMMARY–HDPEAwell-developedendmarketformixedHDPEconsumerpackagingisvisible.VirginplasticsaswellasrecycledHDPEareusedforbottles,jugsforcleaningsupplies,personalhygieneproducts,tubsandvariouschemicals.ArangeofcoloursontherecycledHDPEendproductisacceptableintoday’smarket.TheuseofcarbonblackcausesproblemsasitcannotbesortedbyNIRtechnologyandisthereforenotrecycled.CapsandlidsshouldbemadeinHDPEorLDPEsotheydonotcauseharmtotheendrecyclate.PPisacceptedbutcancreateproblemsintherecyclingprocessifitisnotremovedfromtheHDPEfraction.

6.2.1. HDPEapplicationsHDPEisfoundmostlyinmilkjugs,householdcleanercontainers,shampoobottles,cerealboxlinersandvariousothertypesofbottlesandtubs.HDPEcanberecycledintopens,picnictables,benches,fencing,pipesandothertypesofbottlesandcontainers.128

HDPEhasaclearandevensurfaceandhassomegoodbarrierqualities,thoughitisnotagoodbarriertooxygen.Itisalsodurableagainstshocksandheat.

6.2.2. ColoursHDPEbottlesaretypicallyopaque,althoughtheycanhavemanydifferentcolours.Ideally,theyareunpigmented.Allbottlesareplacedtogetherintherecyclingprocesswheretherecycledplastichasagreyish,blue-greencolourduetothemixingofdifferentcolours.ItispossibletoseparateHDPEintodifferentfractionsbasedontheircolour,butalarge,extensiveMRFisneededforthis.129

AlthoughcarbonblackHDPEbottlesareunwanted,astheycannotbeseparatedintotheirproperwastestream,theyaremorevaluableonthemarkettoday.130MarketsexistforcommonlycolouredHDPEmaterialsoitisthereforeeconomicaltoprocess.131

6.2.3. ClosureSystemsTherearedifferenttypesofcapsthatarenormallyusedonanHDPEbottleandthetypeofcapthatischosenwilldeterminethetypeofmaterialused.PPcapsarecommon,asareHDPEcaps.132Aswithmanyotherelementsinaplasticmanufacturingprocess,thechoiceofclosuresystemsbytheproductmanufacturerisoftendependentonprice.PPcapsarecheaperthanHDPEcapsandarethereforemorewidelyadoptedforHDPEbottles.133

AlthoughasmallfractionofHDPEinPPisokay,smallamountsofPPinHDPEcouldbedetrimental.PPhasahighermeltingtemperaturethanHDPE,whichwillcauseproblemsintheformationofregranulates.However,itisimportanttonotethatthisheavilydependsontheendproductanduseoftherecycled 128NaturalSociety(201).TheNumbersonPlasticBottles:WhatdotheRecyclingSymbolsMean?Website.Availableat:http://naturalsociety.com/recycling-symbols-numbers-plastic-bottles-meaning/129MartinaLehmann,MAKSC130MartinaLehmann,MAKSC131AssociationofPostconsumerPlasticRecyclers(2013).APRDesignforRecyclabilityGuidelinesforHDPE.Availableat:http://www.plasticsrecycling.org/images/pdf/design-guide/HDPE_APR_Design_Guide.pdf132MartinaLehmann,MAKSC133MartinaLehmann,MAKSC


HDPE.IftheHDPEisgoingtobeusedtocreatepipes,PPmaterialinthisfractionwillcauselessstabilityandbreakageofthepipes.Thismaterialcouldthennotbeusedforpipes,aproductthatrequiresstablematerialsthatcanhandlehighpressure.134

AluminiumlidsareonlyacceptableonHDPEbottlesiftheconsumerwilldefinitelyremovethem.

IDEAL GOOD NOTIDEAL BADHDPELDPE

PE(+EVA)

PET(conditional)PP,OPP

PSPVCSiliconeMetals

Table10-CompatibleclosuresystemsforHDPEproducts.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

6.2.4. SleevesandLabelsThesleeveorlabelmaterialonaHDPEbottleishighlydependentonthefinal,recycledHDPEendproduct.Asshallbefurtherexplainedinthefollowingsections,someproductsmadefromHDPEandPPhavequalitiesthatareideal,whileforotherproducts,thismixcouldbedisastrous.ThequestionishowmuchforeignmaterialisokayintheHDPEfraction.Formanyproducts,PPisnotgoodtomixwithHDPE.Inthosecases,aPETsleevemaybebetter.However,forthistobepossible,goodwashingandreprocessingfacilitiesarerequired.135

PSshouldnotbeusedforsleeves,butitcanbeusedforlabels,althoughthisisnotidealeither.

IDEAL GOOD NOTIDEAL BADIn-mouldlabelofcompatiblematerial

PE(MDPE,LDPE,LLDPE)PP,OPP

Paper(conditional)PET(conditional)PS

PSPVCMetals

Table11-CompatiblesleevesandlabelsforHDPEproducts.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

6.2.5. AdditivesandBarriersHDPEdoesnothaveanynaturalgasbarriers,soifthecontentsofHDPEpackagingrequireoxygenbarriers,HDPEinitselfisnotsufficient.136HDPEwithPAorotheradditivesgivesagoodbarrieragainstgases;however,thisisnotarecommendedsolutionfromarecyclingperspective.137

EVOHistherecommendedlayermaterialforHDPEthatwillincreaseitsbarrierproperties.138Asitcannotbeseparated,itwillbepartoftheHDPErecyclate.Althoughthisispotentiallyproblematic,itisgenerallyaccepted.However,thecontentofEVOHshouldbereducedtoaminimum.139


weight)EVOH(<10%oftotal

PA(>1%oftotalpackweight)EVOH(>10%oftotal

134MartinaLehmann,MAKSC135OliverLambertz,Tomra,MartinaLehmann,MAKSC136NinaAckermans,Borealis137Commentfromparticipantatworkshop138AssociationofPostconsumerPlasticRecyclers(2013).APRDesignforRecyclabilityGuidelinesforHDPE.Availableat:http://www.plasticsrecycling.org/images/pdf/design-guide/HDPE_APR_Design_Guide.pdf139AssociationofPostconsumerPlasticRecyclers(2013).APRDesignforRecyclabilityGuidelinesforHDPE.Availableat:http://www.plasticsrecycling.org/images/pdf/design-guide/HDPE_APR_Design_Guide.pdf


packweight) packweight)PVdC

Table12-CompatibleadditivesandbarriersforHDPEproducts.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

6.2.6. SortingandRecyclingRecyclingHDPEisstraightforward.140RecyclingsystemsforHDPEarewidespreadandcommonandthemarketpriceforHDPEisgood.HDPEhasahigh-endmarketvaluetodayandisheavilyrecycled.Therecyclingprocessisnottoocostlyandthefinalrecycledproductisnottooexpensiveforproductmanufacturers.

TherearesomemovementstoreplacePPwithHDPEbecauserecyclingsystemsforHDPEarecommon,moresothanforPP.141However,toprovideHDPEwiththesamefunctionalityandproductprotectionasPP,theHDPEmustbethicker.Thisleadstoalessresourceefficientmaterial.142

TherearedifferencesbetweenHDPEandPPinaMRF.143Somesay6-8%PPinHDPEisacceptable,whileotherssaymax2%.144ThisisdeterminedbywhattheproductsoftheHDPErecyclatewillbe.SomePPintheHDPEfractioncouldbedetrimentalforcertainendproducts.145WhenHDPEandPParemixed,itisverydifficulttoseparatethembecauseoftheirsimilardensities.However,HDPEandPPcanalsobeprocessedtogetherintoPE/PPregranulatetoformhigh-gradeproducts.146HDPEhasameltingtemperatureof130°,whilePPhas160-170°.

PETintheHDPErecyclingstreamisveryproblematicandcancontaminatetherecyclateastheyhaveverydifferentmeltingtemperatures.

140AntoninoFurfari,PlasticsRecyclers141NinaAckermans,Borealis142NinaAckermans,Borealis143OliverLambertz,Tomra144EirikOaland,GrøntPunktNorge145MartinaLehmann,MAKSC146K-online(2016).PlentyofPotentialforRecycling.PressRelease.Availableat:http://www.k-online.com/cgi-bin/md_k/lib/all/lob/return_download.cgi/FA02_Recycling_long_version_Logo_en.pdf?ticket=g_u_e_s_t&bid=3186&no_mime_type=0


6.3. Polystyrene(PS)products

SUMMARY–PSPolystyreneisusedinpackagingforarangeofapplications,howeverisitmostlyusedfordairyproducts.PSisgenerallyusedforsmallpackagingunitsthatconstituteasmallweightedportionofthetotalamountofallpackagingmaterialsconsumed.PSisamarginalpackagingtypeofwhichonlyasmallamountisrecycled.PSinpackagingproductsisnormallythetypethatbreakseasilywhenitiscompressedduringcollection.ShatteredPSandsmallercomponentswillinmostMRFsbethroughameshgriddischargedtogetherwithotherfineparticles.Transparent,whiteandlightcoloursarepreferred,seenfromarecyclingperspective.Itisfurtherrecommendedtousecomponentsthathavealowerdensitythan1g/ccmforlids,caps,sleevesandlabels,ifamaterialotherthanthatofthemainpackagingbodyischosen.PPandPEcanbeseparatedfromPSinthewashingprocess.IfPSischosen,itcanbeseparatedfromthepackagingbodywiththeuseofawindturbine.Aluminiumcomponentsarenotrecommended.

6.3.1. PSapplicationsPSisusedinmanyapplications,thoughitisdecreasinginuse.147Yoghurtcupsisawell-knownapplication.PSisalsousedforcontainerssuchasclamshells,lids,bottles,pots,traysanddisposablecutleries.PSisoftenfoundincompactdisccases,eggcartons,meattrays,yoghurtcontainers,anddisposableplatesandcups.148WhenPSisrecycled,itcanbeusedineggcartons,vents,foampackagingandinsulation.149

PSisinjectionmoulded;vacuumformedorextruded,hasgoodthermoformingproperties,andcanbemadeveryfast.Italsohasagoodstabilityforheat,thoughitisnotflameretardant.150

Expandedpolystyrene(EPS)iseitherextrudedormouldedinaspecialprocessandisdecreasinginuse.151EPSisusedastransportpackaging,forexampleasfishcratesinNorway.EPSissometimesusedtoprotectvaluablegoods,alsoas“chips”,butislessusedassalespackaging.

6.3.2. ColoursPolystyrenecanbeallcolours,butismostlywhite.Theendproductprimarilydeterminesitscolour.152However,forrecyclingreasons,thelesscolourPShas,themorevaluabletherecyclateis.Solid,darkcoloursandthepigmentcarbonblackarenotidealforPS.ThevolumeofPSissosmallandisthereforeseldomrecycledtoday.Forthisreason,differentcolouredPSproductsarenotseparatedoutindividually.

147Commentfromparticipantatworkshop148NaturalSociety(201).TheNumbersonPlasticBottles:WhatdotheRecyclingSymbolsMean?Website.Availableat:http://naturalsociety.com/recycling-symbols-numbers-plastic-bottles-meaning/149NaturalSociety(201).TheNumbersonPlasticBottles:WhatdotheRecyclingSymbolsMean?Website.Availableat:http://naturalsociety.com/recycling-symbols-numbers-plastic-bottles-meaning/150MartinaLehmann,MAKSC151Commentfromparticipantatworkshop152MartinaLehmann,MAKSC


6.3.3. ClosureSystemsAluminiumlidsareacceptableforPSiftheconsumerwillwithoutadoubt,removethem.Aluminiumcancreateproblemsintherecyclingprocess.

Lidsandothertypesofclosuresystemsshouldoppositelysinkorfloatinrelationshiptothebasematerial.InthecaseofPS,lidsshouldbemadefromamaterialthatfloats.Useofclosuresystemsthatarethesamematerialasthecontainer,PS,isdesiredwhenthecoloursarethesame.153

TheliddingfilmonaPScontainercanbemadeupofmanydifferenttypesofmaterials.Commonforallofthemisthattheyarelightweight.PETcancontaminatethePSfractionifitismixedintoit.PSmixedwithvariousothermaterials,suchasPEorEVAisagoodoption.

IDEAL GOOD NOTIDEAL BADHDPE,LDPEPP,OPP

PS,OPS(conditional)

PET PVCAluminium

Table13-CompatibleclosuresystemsforPSproducts.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

6.3.4. SleevesandLabelsSleevesandlabelsonPSpackagingshouldbeminimisedandshouldnotcovermorethan60%ofthepackagingproductinorderforittobecorrectlysortedintheMRF.Theyshouldalsohaveadensityoflessthan1g/ccminordertobeseparatedfromthePSfraction.PShasahigherdensitybutasitisthesamematerialasthepackagingbody,theycanberecycledtogether.

Removablein-mouldlabelsthatdetachinhotcausticwaterareencouragedforPS.154

IDEAL GOOD NOTIDEAL BADRemovablein-mouldlabelPS,OPS

PP,OPPPE

PaperPermanentin-mouldlabel

MetalPVCPET

Table14-CompatiblesleevesandlabelsforPSproducts.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

6.3.5. AdditivesandBarriersCoatingsandlayersaregenerallydiscouragedforPS,unlesstheyarecompatiblewith,oreasilyseparable,inconventionalrecyclingsystems.155Thereislittleinformationonthistopicandfurtherstudiesarerecommended

CalciumCarbonateusedasafillerinPSproductswillincreasethedensityoftheproduct.Densityvariationscandisturbthewashingprocessandinfluencethepropertiesoftheregranulates.Althoughsomesay,itisnotasolutiontofillPSwithCaCO3,furtherimpactstudiesareneededhere.156


weight)PA(>1%oftotalpackweight)

153AssociationofPostconsumerPlasticRecyclers(2013).APRDesignforRecyclabilityGuidelines:AnExecutiveSummary.Availableat:http://www.plasticsrecycling.org/images/pdf/Other-Resins/APR_Guide_Other_Thin_Wall_Packaging_Excerpt_2014.pdf154AssociationofPostconsumerPlasticRecyclers(2013).APRDesignforRecyclabilityGuidelines:AnExecutiveSummary.Availableat:http://www.plasticsrecycling.org/images/pdf/Other-Resins/APR_Guide_Other_Thin_Wall_Packaging_Excerpt_2014.pdf155AssociationofPostconsumerPlasticRecyclers(2013).APRDesignforRecyclabilityGuidelines:AnExecutiveSummary.Availableat:http://www.plasticsrecycling.org/images/pdf/Other-Resins/APR_Guide_Other_Thin_Wall_Packaging_Excerpt_2014.pdf156MartinaLehmann,MAKSC


EVOH(<10%oftotalpackweight)

EVOH(>10%oftotalpackweight)PVdC

Table15-CompatibleadditivesandbarriersforPSproducts.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

6.3.6. SortingandRecyclingPSpackagingisamarginalfractionintheplasticpackagingrecyclingmarket.AtrendhasalsobeenseenofreplacingPSwithothermaterials.PSiseasytosortoutatMRFs,butitisdifficulttorecyclebecausetheweightfractionissosmall,albeitthehugevolume.157Forthisreason,MRFsoftendonotsortoutPSpackaging.Therearefewpost-consumerPSrecyclerstodayasthemarketforPSissmall.158Instead,PSendsupinamixedplasticsfractionoraswasteforincineration.InGermany,thesystemssortoutPSforrecycling,e.g.forinjectionmoulding,butthequalityofthesortedmaterialisoftenpoorandthusnotattractiveforrecycling.TherecyclingmarketforPSisratherlimitedforthesekindsofplasticpackaging,howeveritalsodependsonthetypeofPS.PSNormalandPSHighImpact(HIPS)arethemostvaluablefractionsandthemostcommontypesofPS.159

PShasaspecificweightof1.06g/ccmandcanbedividedfromtheotherplasticfractions.160Ifthedensityishigherthan1.06,itwillmoredifficulttoseparateitfromtheotherplasticfractionsusingtheconventionalprocessesinplacetoday.161

PScancausecontaminationoftheotherplasticfractions,eveninsmallquantities.IfPSismixedwithLDPEiscausesabadsmellanddoesnotblendproperlyinthemeltingprocessastheyhavedifferentmeltingtemperatures.162PSinthePP,fractioncausesimpuritiesandimpactsthequalityofPP.163TherearesomerecommendationsthatinvolveswitchingfromPStoPPentirely.164PSalsohassomehealthrelatedchallenges,influencingtheconversion.However,thismoveisexpensive,asPPcannotbeformedusingPSequipment.165

EPSpackagingfromhouseholdsisnotsortedoutforrecycling.EPSalsoharmsthesortingprocess.

157Commentfromparticipantatworkshop,MartinaLehmann,MAKSC158ThomasEtien,Danone159MartinaLehmann,MAKSC160MartinaLehmann,MAKSC161OliverLambertz,Tomra162MartinaLehmann,MAKSC163MartinaLehmann,MAKSC164ThomasEtien,Danone165Commentfromparticipantatworkshop


6.4. PolyethyleneTerephthalate(PET)Products

SUMMARY–PETTheapplicationofPETinpackagingisincreasingasitreplacesothertypesofmaterials.PETismoreaffordableandhasgoodbarrierpropertiesthataredesiredformanyproducts.PETbottlesarecollectedindeposit-returnsystemsinNorwayandSwedenandarerecycledtoproducenewbottlesorotherhighvalueproducts.Separatefromthedeposit-returnsystems,PETisstillalargefractionofthemunicipalwastestream,thoughthequalityisamixofdifferentcolouredbottles,trays,tubsandotherthermoformedpackaging.ThemarketforPETrecyclingneedstobefurtherdeveloped,especiallyforthermoformedPET-filmed,asthereisnofunctioningrecyclingmarketontheseapplicationsforthemomentinEurope.Inthesecircumstances,focusingondesignforrecyclingcouldplayanimportantrole.Thefollowinggeneralrecommendationsaregiven:

- Choosetransparentandlightcoloursifpossible- Chooseclosuresystemsandsleeves/labelsthataremadeofPP/OPPandPEthatcanbe

separatedfromPETinthewashingprocess.- Avoidtheuseofbarriermaterialsifpossible.

6.4.1. PETApplicationsPolyethyleneterephthalate,commonlyabbreviatedPET,PETE,ortheobsoletePETPorPET-P,isthemostcommonthermoplasticpolymerresinofthepolyesterfamilyandisusedinfibresforclothing,containersforliquidsandfoods,thermoformingformanufacturing.166

PETisacombinationoftwomonomers.PETGisofthesamechemicalcompositionasPETbutwiththeadditionofglycol.Withjustthisoneaddition,thechemicalcompositioniscompletelychanged,creatingacompletelynewplastic.167rPETreferstoPETmadefromrecycledmaterial.AlthoughthetermrPETisoftenusedforpackagingwhichincludesaquantityofrecycledmaterial.

ThevolumeofPETpackagingisincreasing.PEThasreplacedglassandPVCbottlesandhasalsostartedtoreplaceotherpolymers,forexample,PEandPP.PEThasgoodbarrierproperties,butforsomeapplications,thereareneedsforevenbetterbarriermaterials.

BecausePETisanexcellentwaterandmoisturebarriermaterial,plasticbottlesmadefromPETarewidelyused.Collected PETbeveragebottlesforfoodcontactintheNordiccountriesaremainlypartofdeposit-returnsystems.Somebeveragebottlesalsoendupinthegeneralplasticpackagingwastestreamorasresidualwaste.OtherPETbottlescollectedisamixofsomedepositbottles,bottlesforotherfoodandnon-food.PETfilm/thermoformedpackagingsuchastubs,potsandtraysisafastgrowingapplication.

ThebestqualityofPETpackagingforrecyclingisthefood-gradePETbeveragebottles.Theseshouldbetransparent.TheNordicdeposit-returnsystemscollectmostofthesebottles.Otherbottles,partlynon-food,representalower,butstillarelevantquality,dependingonqualitycriteriaforrecycling.AllotherPETfractions,andmixes,canstillbecharacterizedasmorechallenging,againalsodependentonqualitycriteria.

Theintrinsicviscosity(IV)variesbetweenPETapplications:bottles:0.8IV;films:0.7IV;fibres:0.6IV;straps:0.9IV.Thismeansintheorythatbottlesandthermoformedfractionsshallnotberecycled

166Wikipedia,PET167Wheaton


togetherwithoutalteringthepropertiesoftheplastic.Inpractice,someofthePETthermoformedapplicationshavebeensortedouttogetherwithPETbottles.Toacertainextent,thishasbeenacceptedinthemarket,atleastmonolayerPET.

6.4.2. MarketsThemarketsforallPETpackagingarecharacterisedingeneralbyfallingrawmaterialpricesandseveralnewpackagingsolutionswithdifferentproperties.PETpackaginghastwomainsegments:

• ThePETbottle-to-bottle(B2B)recyclingmarketworkswell.Thismarketischaracterizedbystrictqualityspecificationsandhighprices.Thedeposit-returnsysteminNorway(Infinitum)andSweden(Returpack)hasverystrictrules,andpenalties,relatedtodesignforrecyclability.

• AllotherPETpackagingproducts,sortedoutasdifferentmixes,arepartlyrecycledtofilmandfibres.PETthermoformsaredifficulttocharacterizeanditisthereforedifficulttosortmonolayersfrommultilayers,andbetweendifferentmultilayers.DuetodifferentpropertiesofdifferentPETapplications,incl.theintrinsicviscosity,andtheuseofmultilayers,therecyclingprocesseshaveconsiderablelosses.

Recycledmaterial,approvedforfoodcontact,obtainsthebestpricesinthemarket.ColourlessPETispartofawell-functioningmarket,whilecolouredPETmarkethasaweakmarketandoutlets.

6.4.3. ColoursAstheoutletofrecycledPETismostlytransparentorlightlycolouredbottlesandtrays,therecyclingmarketislessinterestedinstronglycolouredPET.TherecyclingofcolouredPETisthusachallengebecausethereisalimitedendmarketfortheseproducts.Inadditiontothis,suchstrongcolouringcanharmtherecyclingprocess.168Opaquewhitebottleswithtitanium(TiO2)alsoharmsomerecyclingprocesses.

Lightcoloursarethusacceptable,whiledarkercoloursmightbesuitable.Carbonblackandopaquecoloursarenotacceptable.

6.4.4. ClosuresystemsPPandPEaretherecommendedmaterialsusedforclosuresystemsonPET.SomePETtypescannotbeusedforcaps,astheyarenotmadeforinjectionmoulding.SomesaysthatPETshouldbeavoidedinclosuresystemsaltogether.169

AliddingfilmthatcanbecompletelyremovedbytheconsumeristhepreferredoptionforPETthermoformedtrays.IfthiscannotbeguaranteedthenaPETliddingfilmisrecommended.170Moreknowledgeisneededtofindouthowmuchofthesefilmsareremoved,inpractice.

IDEAL GOOD NOTIDEAL BADPP

PE* PET(conditional)

MetalsPSPVCSilicons

Table16-CompatibleclosuresystemsforPETproducts.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

168AntoninoFurfari,PlasticsRecyclers169MartinaLehmann,MAKSC170RECOUP(2016).PlasticPackaging.RecyclabilitybyDesign.TheEssentialGuideforallthoseInvolvedintheDevelopmentandDesignofPlasticPackaging.http://www.recoup.org/p/130/recyclability-by-design


*HighlyfilledPEisdeemedunfit.PElaminateisunfitforPETtrays.

6.4.5. SleevesandlabelsThedesignofsleevesandlabelsareimportantforbothsortingandrecycling.Forthesorting,itisakeyissuethattheNIRinstrumentcanidentifythePETbottles.Inpractice,thesleevethusshalljustcovermaxabout60%ofthebottle.

Fortherecyclingprocess,itisimportantthatthesleevescanbeseparatedbydensity,fromthebottle.Forsplittingthesleevefromthebottleinthewashingprocess,thesleeveshallhaveadensityoflessthan1g/ccm,forexample,OPP.PVClabelsareespeciallyundesirablebecauseofthepoorthermalstabilityofPVCwhenmixedwithPET171.ItisdifficulttoseparatePETfromPVCbecausetheirdensitiesareverysimilar.172

PolyolefinlabelsareidealforPET,soPPorPE.PEisespeciallyidealforsleevesasitcaneasilyberecognisedbytheNIRscannerasamixofPETandPE.173PPisidealforlabels.

APETsleeveonaPETbottle,althoughitcaneasilybesortedintothePETfraction,isnotanidealcombination,asthesleevecannotbeseparatedfromthebottle.Thepropertiesofthebottlearedifferenttothesleeveandcouldcausetroubleintherecyclingprocess.

Furthermore,asleevelabelmustnotdiscolourthePETflakeorplaquesmouldedfromPETflakes174.PrintinginkscancontaminatewashwaterandstainPETflakes175.

IDEAL GOOD NOTIDEAL BADPP,OPPPE

Removablein-mouldlabelEPS

PaperPET*Permanentin-mouldlabel

MetalPSPVC

Table17-CompatiblesleevesandlabelsforPETproducts.Thecoloursillustratethecompatibilityofeachoption,withdarkgreenlistedasideal,greenasacceptable,orangeaslessideal,andredasproblematic.

*FoamedPETorPETgisokay

6.4.6. AdditivesandBarriersPEThasinmanycasesgoodbarrierproperties,andinsomecases;thereislittleneedforadditionalbarriers.AthickerPETmaterialcanimprovethebarrierandatthesametimebeagoodmeasuretoimproverecyclability.

ThebestoptionsforinsertsisHDPE,LDPE,PPandPET/paperasasecondbestoption.SolutionsthatarenotsuitablearePVC,PS,EPS,PU,PA,PC,PMMA,orthermosetplastics/metallic176.

171AssociationofPostconsumerPlasticRecyclers(2016).SelectingShrinkSleeveLabelsforPETPackaging–anAPRDesignGuideBulletin.Availableat:http://www.plasticsrecycling.org/images/pdf/design-guide/Technical-Bulletins/APR_PET_Sleeves_Tech_Bulletin.pdf172MartinaLehmann,MAKSC173OliverLambertz,Tomra174AssociationofPostconsumerPlasticRecyclers(2012).PrinciplesforSleeveLabelsonPETBottles.Availableat:http://www.plasticsrecycling.org/images/pdf/PET-Resins/PET-Bottles/principles_for_sleeve_labels_on_pet_bottles.pdf175AssociationofPostconsumerPlasticRecyclers(2016).SelectingShrinkSleeveLabelsforPETPackaging–anAPRDesignGuideBulletin.Availableat:http://www.plasticsrecycling.org/images/pdf/design-guide/Technical-Bulletins/APR_PET_Sleeves_Tech_Bulletin.pdf176RECOUP(2016).PlasticPackaging.RecyclabilitybyDesign.TheEssentialGuideforallthoseInvolvedintheDevelopmentandDesignofPlasticPackaging.http://www.recoup.org/p/130/recyclability-by-design


6.4.7. SortingandrecyclingRecyclingofPETistheonlyexampleonlargescalewherethecircleisclosedatthehighestlevelandwherenewhighqualitypackagingcanbemadeoutofrecycledresin.RecycledPETbottlesareusedtomakenewbottlesandthermoforms.PETthermoforms(mainlytrays)whichareproducedwithacontentofr-PET(recycledPET)oftenabove70%arefullycomplyingwithfoodcontactregulations.177However,duetothevarietyofPETpackaging,withquitedifferentproperties,therearemanychallengesrelatedtobothsortingandrecyclingofPET.PETthermoforms(traysandotherapplications)havedifferentpropertiesfromPETbottlesandarethusnotrecyclabletogether.MonolayerPETtraysaremorefragileandhavedifferentmeltingtemperatures.Anacceptable,butnotideal,limitofPETfromotherproductsinthePETbottlerecyclatefractionis10%.However,thispercentageisdisputedoratleastnotacceptedbyallrecyclers.

Thereisresearchunderwaytofindtechnicalsolutionstomeetthesechallenges,evenforthermoformedPETproducts.Thesethermoformedapplicationscanbemonolayerormultilayers.However,thesetwoproductsaredifficulttosplitbysorting.ThemultilayerPETfractionhasnotbeenregardedrecyclableduetotechnologicalchallengesandbecausetherehavebeennoendmarketsfortherecycledproduct.Forexample,Solayr-aSpanishrecycler,offerssolutionsformultilayerPETtrays.Moreinformationisneededtoevaluatethesesolutions.

PETiseasilycontaminatedandharmedbyotherplasticsthatmaketheirwayintothisfraction,butalsobyglassfragments,dirt,grit,paper,glues,andproductresidues.178Aslittleas20ppmPEinaPETbottlecancauseproblems,dependingonthequalitystandardsandthetypeofendproduct.179PEhasalowermeltingpointthanPET(120vs.200)whichmeansthatasthemeltstartstosolidify,thePEwillcausedefectsonthebottle.180

DuetoverysimilardensitytoPET,itisverydifficulttoseparatefromPET.Yet,asmallpercentageofPVCwouldbedetrimentaltoanyPETrecyclingprocess.However,thereislittlePVCpackagingleftintheNordicmarkets.

177PetcoreEurope(2015).PetcoreEuropeOrganisedWorkshoponRecyclingRigidPETThermoformsinBrussels.PressRelease.Availableat:https://petcore-europe.prezly.com/press-release-petcore-europe-organised-workshop-on-recycling-rigid-pet-thermoforms-in-brussels178PetcoreEurope(2014).RecycledProducts.Availableat:http://www.petcore-europe.org/recycled-products179MartinaLehmann,MAKSC180MartinaLehmann,MAKSC


7. Attachments

7.1. AbbreviationsandDefinitions

Abbreviation DescriptionAlkaliconditions ConditionsthathaveapHgreaterthan7B-OPP BiaxialorientedpolypropyleneCrystallinestructure Ions,moleculesoratomsheldtogetherinanordered,3DarrangementDensity Themassperunitvolumeofasubstanceunderspecifiedconditionsof

pressureandtemperature.Deposit-returnsystem Asurchargeonaproductwhenpurchasedandarebatewhenitis

returned.EPBP EuropeanPETBottlePlatformEPS ExpandedpolystyreneEuPIA EuropeanCouncilofPaint,PrintingInkandArtists’ColourIndustryEVA EtylenevinylacetateExtrusion RawplasticismeltedandformedintoacontinuousprofileEVOH Ethylenevinylalcohol,acopolymerandplasticresinHDPE HighdensitypolyethyleneHydrocalcite Ahydrousformofcalciumcarbonate,CaCO3H2OInjectionmoulding Amanufacturingprocessforproducingpartsbyinjectingmaterialintoa

mould.IV Intrinsicviscosityisthemeasureoftheflowtimeofasolutionthrougha

simpleglasscapillaryLaminate Alsolamination.Techniqueofmanufacturingamaterialinmultiplelayers,

sothatthecompositematerialachievesimprovedstrength,stabilityorotherpropertiesfromtheuseofdifferingmaterials.

LDPE LowdensitypolyethyleneLLDPE LinearlowdensitypolyethyleneMeltingpoint Meltingpointofasolidisthetemperatureatwhichitchangesstatefrom

solidtoliquidatatmosphericpressureMonolayer Asingle,closelypackedlayerofatoms,moleculesorcellsMonomaterial MadefromasinglematerialMontmorillonite TypeofnanoclayMunicipalsolidwaste ConsistsofeverydayitemsthatarediscardedbythepublicMRF MaterialrecoveryfacilityNanoclays NanoparticlesoflayeredmineralsilicatesNanofillers Adopingagentinthematrixofacomposite(materialwith2ormore

phases),whoseindividualelementshaveatleastoneoftheirdimensionsinthenanoscale

NIR NearInfrared(radiation)OPP OrientedpolypropyleneOPS OrientedPolystyrenePA Polyamide(nylon)PC PolycarbonatePET PolyethyleneterephthalatePETG PolyethyleneterephthalateglycolPLA PolyacticacidPMMA PolymethylmethacrylatePolyolefins Anyclassofapolymerproducedfromasimpleolefinasamonomer.


ExamplesarePEandPP.PP PolypropylenePS PolystyrenePU PolyurethanePVdC PolyvinylidenechloridePVC PolyvinylchloridePVOH PolyvinylalcoholRecyclate Rawmaterialsentto,andprocessedin,awasterecyclingplantormaterials

recoveryfacilityRegranulates Plasticgranulesarethebasicproductfromwhichplasticproductsare

made.Regranulatereferstorecycledplasticfromproductionwaste.Solvent-basedprimer Oil-basedinkStiffness TherigidityofanobjectTensilestrength Thecapacityofamaterialorstructuretowithstandloadsoftendingto

elongateThermoforming Aplasticsheetisheatedtoapliableformingtemperature,formedtoa

specificshapeinamould,andtrimmedtocreateausableproduct.Vacuum-forming Simplifiedversionofthermoforming,whereasheetofplasticisheatedtoa

formingtemperature,stretchedontoasingle-surfacemould,andforcedagainstamouldbyavacuum.

Water-basedprimer Water-basedinkWindturbine UsedinMRFstoseparatelightweightplasticsfromplasticsthathavea

higherdensity.Yield Themeasureofafilmscoverageperunitweight.


7.2. DescriptionofTypesofPlasticsThetablebelowliststhekeyplastictypes.Eachtypehasitsnumber1-6whilenumber7comprisesothertypes.Thesenumbercodesareusedinternationally.Onavoluntarybasis,plasticconvertersoftenmarkthepackagingwiththesesymbols.Itisimportanttostressthatthesesymbolsarenotusedforsortingplasticpackagingbecausethissortingisdoneautomaticallybysortingmachinesandbecausealmostallplasticpackagingisincludedinthecollectionsystems.Insomecountries,thecollectionislimitedtojustafewofthenumbersonthelist.GreenDotNorwayandFTIABrecommendindustrytousenationalconsumerfriendlymessagesandothersymbols.

Code Name and Abbreviation

Density Properties Usage areas

Polyetylene terephthalate (PET) (PETE)

1.34-1.39 • Clear and smooth surface • Barrier against air and

water • Durable against shocks

and heat

Widely used for drink bottles, but also as packaging for other products, including trays and cups.

High Density Polyethylene (HDPE)

0.91-0.94 • Rigid and tough material • Good properties in terms

of solvents • Stretchable

Widely used for bottles, also for chemical products. Heavily used in building materials and in car parts.

Polyvinylchloride (PVC)

1.16-1.30 • Resistant against fats and oils

• Very strong material

Mainly used within construction for pipes, flooring, but also for garden furniture, shower curtains and toys. Found in rigid and soft products

Low Density Polyethylene (LDPE) Linear Low Density Polyethylene (LLDPE)

0.91-0.94 • Good durability in relation to acids and organic oils,

• Transparent

Used carrier bags, food packaging, and transport packaging.

Polypropylene (PP)

0.90-0.92 • Good container for acids, alkalis and solvents

• A strong material with a high melting point

Moulded products for buildings, cars and EE. Flexible, and rigid packaging products.

Polystyrene (PS)

1.04-1.09 • Good protection against liquids that have a short life time

• Rigid- and foam shaped • Poor transporter of heat • Low melting temperature

Often used for food packaging and for drinks. EPS is used for isolation.

Acrylonitrile butadiene styrene, (ABS) Polyamide (PA) Polymethyl methacrylate,

Other plastic types 181 and laminates 1.13-1.15

• A range of different types of plastics with varying properties.

Products that are base don other types of plastic or a combination of plastics, for instance laminated plastics used for packaging.

181http://plastics.inwiki.org/Polymer_abbreviations,tabledevelopedbyMepexfor“øktressursutnyttelseavplastavfall”,areportfortheNorwegianEnvironmnetalAgency,2012


Code Name and Abbreviation

Density Properties Usage areas

(PMMA) Polyurethane (PUR) Styrene-acrylonitrile (SAN)

Table18–Explanationofplastictypes(AmericanChemistry).

Theclassificationsinthetableaboveareindependentoftherawmaterialbeingused,whetheritbefossil-basedorbiobased.Inadditiontothese,newmaterialsaredevelopedcontinuously,biodegradableoptionsandcombinationsthatdonotnecessarilyfallwithinoneofthecategorieslistedinthetable.Thiscanbeachallengeintermsofsortingandrecyclingofpredefinedmaterialqualities.


7.3. SortingandRecycling

Knowledgeofthesortingandrecyclingprocessesforplasticpackagingisvitaltotheunderstandingofwhatmaterialtypescanbeseparatedfromthewastestreamandrecycledintonewproducts.Itisalsoimportanttounderstandthatsortingandrecyclingfacilitiesaredifferent,andthatnofacilitiesareidentical.Theyaredesignedandoperatedindifferentways.Ingeneral,thisreportfocusesonpost-consumerplasticpackaging.

Whenmixedplasticpackagingiscollectedseparatelyfromhouseholds,itissenttosortingfacilitieswheretheaimistosortthewasteintodifferentelementsthatcanberecycledandtherestusedforenergyrecovery.Automaticsortingtechnologyisusedtoseparatetheplasticpackagingintoindividualmaterialfractions;e.g.PETbottlesinonestream,LDPEpackaginginanother,andrigidPPpackaginginathird,etcTheaimforthesortingprocessesisalsotoremoveimpuritieslikefoodwaste,papierglass,metalandotherwastes,and.

PlasticpackagingfromNorwayandSwedenisoftensenttoacleanmaterialrecoveryfacility(MRF)inGermanywherethisinputisonlyasmallpartofitstotalcapacity.Therearedifferencesbetweenplantsofhowadvancedthesortingsystemsare,andresultshaveshownquitelargevariations.

ThesamesortingtechnologyusedinMRFsforplasticisusedinfacilitiesforseparatingplasticmaterialsfrommixedresidualwasteinadirtymaterialrecoveryfacility(MRF)alsocalledMixed-wasteprocessingfacility(MWPF).ThisisnotacommonsolutioninNorwayandSweden,butthiswillprobablybefurtherdevelopedandexpandedinthefuture.ThefirstplantisinoperationinNorway(ROAF),oneplantunderconstruction(IVAR,Stavanger)and3moreintheplanningphase.

Sortingplantsincludeacombinationofdifferenttechnologies:

• Drumswifterforsizesorting• Ballisticseparator• NIRdetectors• Wind-sifter• Metaldetectors

Thesortedqualitiesofplasticsarenormallysentfromsortingplantstoseparatewashingandrecyclingplants.Inthisstage,separationtechnicsareusedtoproduceaqualityforrecyclingandwillnormallyinclude:

• waterbathseparatorwithasink/floatprocess• dryingandwind-siftertoseparatelighterpiecesofplasticfilmandpaperfromheavierpieces• extruderwithfilterstoremoveimpurities

Materialpropertiesarevitalforthesortingandrecyclingabilityindifferentprocesses.DifferentmaterialshavedifferentNIR-reflections,differentdensitiesanddifferentmeltingpoints;allimportantfactorsforsortingandrecyclingprocesses.Thesepropertieswillbediscussedinthefollowingsections.

ThebulletpointsbelowexplainwhatcanhappentoaHDPEbottlewithaPETsleeve:

- TheproductisincorrectlyidentifiedasPETthroughapositivesortingprocess- TheproductisnotidentifiedasunwantedinthePETstreamthroughnegativesortingandends

upasacontaminantinthePETfraction.- InthewashingfacilityforPET,HDPEwillfloatandbeextractedfromthePETfraction,leadingtoa

lossinthismaterialfromthecirculareconomy.- SomeHDPEwillremaininthePETstream.


- TheremainingHDPEwillmeltat130Candwillnotbeseparatedthroughfiltering,butendupinthefinalPETrecyclateasacontaminant.

Theremainingplasticmaterialthathasnotbeensortedintoamaterialfraction,endsupinamixedplasticsfractionthatisdifficulttorecycle.Someofitwillalsoendupinthewastestreamforincinerationorlandfill.

7.3.1. NIRsortingtechnologyinsortingplants(MRF)NIRtechnologyisusedtoidentifyplasticmaterialtypesandformsthebasisofensuringthattheyendupintherightfraction.NIRstandsforNearInfra-Redandisusedasastandardforsourceseparatedpackagingmaterialandin60-70%ofallMRFstoday.182However,fewplantsarefullyautomated,e.g.somesortingandqualitycontrolisstilloftendonemanually.NIRdetectorscanrecognisedifferenttypesofplasticsbyreadingtheirreflectionatthe“surface”oftheproduct.Eachmaterialtypehasaspecificreflectionwitharangethatcanberecognised.TheNIRdetectorcanbeoptimisedtoidentifyandsortawiderangeofpackagingstructures.183Itcanalsodetectdifferenttypesofthinmulti-materialstructuressuchasPET/PEandPE/PAbasedonthereflectiongoingintothematerialandthinfilmlayers.However,ingeneral,laminatedfilmstillisregardedasachallenge.Inthesameway,theNIRtechnologyneithermanagestosortmonolayertraysfrommultilayertrays.

TheNIRdetectorworkscloselywithjetsthatblowoutcompressedair.Thesejetsareusedto‘blow’thevariousmaterialtypesintotheirrespectiveplasticstreams.Thecompressedaircanvaryinstrengthdependingontheweightofthematerialthatis‘blown’out.Thisway,heavyunitswithresiduescanavoidbeingseparatedtoreducethechanceofcontamination.ThelistbelowshowswhattheNIRtechnologycanidentify:

- Materialtypes:PE,PP,PET,PS,PVC,etc.- Productshapes:bottlesandtrays- Colouredplastics:clear,opaqueandsolidcolours- Specificbrandedproducts:canremovespecificunwantedpackaging- Weight:removepackagingwithresidues

Forproductsthatconsistofvariousmaterials,suchasaHDPEbottleswithaPETsleeveandaPPcap,theNIRdetectorcouldmistakenlyidentifytheproductandsenditintothewrongfraction.Sleeves,labels,caps,andfilmmadefromadifferenttypeofmaterialthanthepackagingproductbodycancontributetoincorrectsorting.Ifthesecondarymaterialcoversalargepartofthesurfaceofthepackagingbody,thehigherthechanceisofincorrectsorting.

NIRtechnologyhasbecomeincrediblyusefulintheseparationofplastics,howevertherearealsoseveralchallengesassociatedwiththistechnology.TheNIRdetectorcannotdetectmaterialcontainingthepigmentcarbonblack,norcanitdetectmaterialcombinations(filmonrigidpackaging,sleevesandlabels,multilayertraysetc.).Technologywiththeabilitytosortblackplasticwithcarbonblackpigmentisunderdevelopmentandthereareseveraltechnologysuppliersthatcouldpotentiallybeonthemarketinthenearfuture.Sofartheexperiencefromoperationsislimitedandthesolutionsforthemarketarenotyetavailable.

Asortingplantcanbuildupitsowndatabaseofmaterialspectrumsthatitcanidentify,thiswayallowingformorematerialtobesortedandrecycled–localproductscanbecommoninsomeareaswhilstunknowninothers.Itisexpectedthat70-90%ofalltheplasticthatentersasortingplantwillbesorted 182OliverLambertz,Tomra183McKinlay,R.andMorrish,L.(2016).REFLEXProject–ASummaryReportontheResultsandFindingsfromtheREFLEXProject.AxionConsulting.


intoitscorrectmaterialstream.However,everytimetheNIRdetectorisadjusted,otherfractionsthataresimilar,arelostfromthewastestream.184Theoperationisthusoptimizedcontinuously.

Positiveseparation,whichidentifiesthesought-afterplasticmaterialtypes,isusedincombinationwithnegativeseparation.Negativeseparationisusedtoremoveunwanteditemsandtofurtherincreasethequalityofthematerialstreamssortedforrecycling.

Sortingfacilitiesareoftenassessedbasedontheirfunctionalabilities,whicharegenerallybasedontheoverallyieldandquality(purity)oftheplastic.Therecyclingyieldisregardedastheproportionofaspecifictypeofplasticpackagingthatcanbeseparatedandsenttorecycling.Contaminationsinthematerialstreamarenotincluded.Plasticpackagingthatcontainsalargeamountofresiduesareunwantedbecauseoftheircontentsofeitherchemicals(thatcaninfluencerecycling),orfoodthatcontributestosmellandgrowthofbacteria.

Thepurityofamaterialstreamspecifieshowmuchofthestreamhasbeencorrectlysorted(inwt%).Thespecifiedyieldandqualitynormallyincludesmoistureandproductresidues.Theseparationefficienciesforflexiblepackaging,includingtrays,comparedtorigidpackagingarelessthanwouldbeexpectedduetothebehaviourofthelightweightmaterialonthesortingbelt.185Yieldandqualityarecontrolledbytestingtheoutgoingmaterialstreams,andoftencomparingthemtothematerialthatcomesintothesortingplant.Therearemanyteststhatdocumenttheyieldandqualityofdifferentmaterialtypesthatcomeoutfromthevarioussortingplants.

Materialtype Yield(%) Quality(purity)(%)

PE-film(incllaminatedPE) 84-89 93-96

HDPE 74-80 97

PP-rigid 70-75 96-98

PET-bottles 70-75 97

PET-pots/trays/tubs(incl.film) 60-62 97

Table19–Anexampleofyieldandquality(purity)fromasortingplantinNorway.

7.3.2. WashingandrecyclingtechnologyWaterbathtechnologyisanadditionalwayofseparatingplastictypesandimpuritiesfromeachother.Priortothewaterbaththathasasink/floatprocess,plasticpackagingproductsarecrushedintosmallerplasticflakes,10-15mminsize,makingthemeasiertoseparate.

Plasticpackagingmaterialshavedifferentdensitieswhichcanbeusedtoassistintheirseparation.Sink/floattechnologyisusedinwashingfacilitiestoupgradethequalityoftheofthepre-sortedplasticmaterial.Inconventionalwashingfacilitiesusinghotorcoldwater,heavierplasticswillsinkandcanbeseparatedfromthelighterplasticsthatfloat.

Mostofthesecondarymaterials,suchaslabels,sleeves,glue,caps,etc.areremovedduringthisprocess.Thisalsoincludesproductresiduesthatarewatersoluble.Thefollowingtableshowsthedensityofeachpolymerandtheirbehaviourinthesink/floatprocess.186

184Commentfromparticipantatworkshop185McKinlay,R.andMorrish,L.(2016).REFLEXProject–ASummaryReportontheResultsandFindingsfromtheREFLEXProject.AxionConsulting.186Plasticpackaging,Recyclabilitybydesign.Recoup2015


Table20–Polymertypes,theirdensities,andtheirbehaviourinthesink/floatprocess.

Colourpigments,fillersandotheradditivescanimpactthedensityofaplasticandcontributetolesspreciseseparationinthesink/floatprocess.BiobasedplasticssuchasPLAthathaveadensityhigherthan1,canhaveasimilardensitytoPET,makingitpossibleforthetwomaterialstoendupinthesamefraction.ItiscrucialthatPLAisnotrecycledtogetherwiththePET.

Windsiftersareusedafterwashinganddryingtoseparatethin,lightfilm,paper,andothercontaminants,fromthethicker,rigidpackaging.Theyarevitaltoupgradethematerialstreamstoseparateheavyfractionsfromthelighterones.

Thefollowingtableliststhevariousunits,withadescriptionoftheirfunction,thatareoftenfoundinwashingfacilities.

Component Function

Crusher Opensthebalesandcoarselygrindsthematerial(80mm).Canbesupplementedwithamagnettoremovemetals.

Pre-washer Removesmostoftheproductresiduesandheavyparticles

Wet-mill(crusher) Crushesthematerialtofragmentsof10-15mminsize

Frictionwasher,warmwater(turbowash)

Gluesandlabelsareremoved

Separationtankandcentrifuge

Separatesplasticsofvaryingdensities.Heavyplasticsareefficientlyseparated(PET,PVC)fromlight,floatingplastics(PE,PP)

Dryer Driestheproduct

Windshifter Contaminantssuchaspaperorfilmareremoved

Extruderwithfilter Meltstheplasticmaterialandproducesflakes.Differentfilterscanleadtodifferentlosses.Lossofmaterialcanvaryfrom2-6%.

ThereisalsoapotentialtouseNIRdetectorstosortflakesfromamixedmaterialcompositionwithdifferentplastics.Toproducefoodgradematerialthereisneedforspecialprocessestoupgradetherecycledmaterial.TheseprocessesaremostcommonforPET-recycling.

Aftertheplasticshavebeenshredded,washedandthefragmentshaveundergoneprocessestoeliminateimpurities,thematerialismeltedandextrudedintotheformofpellets.Themeltingtemperaturevariesbetweenplasticmaterials,from130Cto250C.Ifastreamofplasticwithlowmeltingtemperatureiscontaminatedwithplasticwithahighmeltingtemperature,thecontaminantswillnotmeltandcan


decreasethequalityoftherecyclateifitisfilledwithgrainsforexample.PETimpuritiesinPEandPPwillhaveabiginfluenceonthequalityoftherecycledPE/PP.Someoftheparticleswillberemovedinthefiltersthathaveawidthof0,1-0,3mm.Thepelletsarethenusedtomanufactureotherproducts.Itisageneraltrendintherecyclingmarketthatcustomersrequirehigherqualityplastics.

Testsandcalculationshavealsobeenmadeofmaterialthathascomeoutofthewashingandrecyclingprocess.Thisprocesshasseveralareaswherethereisalossofcontaminants,unwantedplastics,andasignificantamountofplasticmaterialthatisfullyrecyclable.Itisdifficulttospecifytheamountsoflossineachfraction.Incomingmaterialcouldconsistof5-10%productresiduesandmoistureand5%materialthathasbeenincorrectlysorted.10-15%oftheincomingmaterialisthereforenoteligibleforrecycling.Thefollowingspecificationsareexpectedtobefulfilledforacompletewashingandrecyclingfacilitywithsink/float,windshifterandextruder:

Materialtype Yield Quality(purity)

Film 65-70% Min99,7%

HDPE 75-78% Min99,7%

PP 70-75% Min99,7%

Table21-Anexampleofyieldandquality(purity)fromarecyclingfacility.

7.3.3. Outlinedescriptionofmarketforrecycledplastics

Material MarketdescriptionRigidPP

PPisrecycledintoseveralproducts.ThereisagoodmarketforPP-recyclingbothinEuropeandintheFarEast.RecyclersnormallyseparatethedifferentgradesofPPmaterialbeforeprocessing;thiscreatesabetterqualityproductforonwardsaletomanufacturers.

HDPE HDPEisacommonlyrecycledplasticmaterial.AlmostallEuropeancountriescollectHDPEpackagingforrecycling.Recycledmaterialispartlyusedaslong-livedproductssuchaspipes,partlyaspackaging.

PS ThemarketforrecyclingofPS-packagingislimitedandnotwelldeveloped.ThecontentofPSinamixedplasticpackagingstreamisnormallylimitedandhasoftennotbeensortedoutatsortingplants.PSisalsooftencrushedintosmallerpiecesandallpieceslessthan50mmarenormallyremovedinaresidualfraction.

PET About50%ofallPETbottlesinEuropearerecycled,partlyintonewbottles,partlyintosheetsandfibres.Bottlesareingeneralsuitableforrecycling.ThePETbottleproducersandbrandownersareingeneralclevertofollowtheindustryguidelinesforrecyclability,EPBP.However,newPETbottleswithaspecialbarrierformilkproductsarenotrecyclabletodayandarethussortedoutforincineration(caseFrance).Thermoformedplasticsliketraysareeithermonolayerormultilayer.MonolayerPET,mighttoacertainextent,5-10%,bemixedwithPETbottlesforrecycling.MultilayerPETpackagingisdifficulttorecycle.Technologiestosplitordissolvethelayersareinprogress.However,multilayersandmixesareforthemomentoftenincinerated.ChemicalrecyclingisanoptionforclearandcleanPETflakes,e.g.verystrictqualitycriteria.


LDPE-film ThereisagoodglobalmarketforrecyclingofLDPEfilm,especiallyclearfilmfromcommercialsources.Pricesforrecycledplasticsoftherightqualityarequitehigh,butthereisalargedifferenceinpricesdependingonquality.Mixed,colouredPE-filmfrompost-consumerplastichasalimitedmarketandthepricesareverylow.TheproductionofLDPErecyclatefromhouseholdplasticpackagingislimitedandthepriceslow.Inpractice,recyclersoftenmixLDPEofdifferentquality.

PP-film InEurope,thereisnospecificrecyclingmarketforPP-film.However,thebottleneckforPP-filmrecyclingisthemissingdemandfortherecyclate.UsersofPP-filmhavenormallyhighrequirementsrelatedtocolour(clear/light)andfoodcontact.


7.4. Biobased,Oxo-degradableandBiodegradablePlastics

ThistextgivesmoreinformationtothesummarygiveninChapter4.11.ThischapterisbasedontheMepexreport“Sourcesofmicroplastics”commissionedbytheNorwegianEnvironmentalAgencyandpublishedinDecember2014.Inaddition,werefertothreerecentstudiesrelatedtorecyclingandrecyclability.

Plasticitemsdegrade,somemoreslowlythanothers,dependingonthekindofplastics,theadditivesusedandofcoursetheconditionswherethedegradingtakesplace.Inordertoimprovethequalityoftheplasticproducts,avoiddegradationandthusprolongtheirlife,specialadditivesareused,forexampleinproductsthatareexposedtothesun.Inrecentyears,othermaterialshavebeenaddedfortheoppositereason,tostartaprocessofdefragmentingtheplasticsasabasisforfurtherdegradation.

Thereissomeconfusionofthedefinitionofbioplasticsvs.biodegradableplastics187:

• Bioplasticsencompassesawholefamilyofmaterials,whichdifferfromconventionalplasticsinsofarastheyarebiobased,biodegradableorboth.

• Thetermbiodegradablereferstoachemicalprocessduringwhichmicroorganismsthatareavailableintheenvironmentconvertmaterialsintonaturalsubstancessuchaswater,carbondioxideandbiomass.Artificialadditivesarenotneededhere.

Thefollowingtableonbiobasedandbiodegradableplasticsillustratesthedifferencesfurther,alsowithsomeexamplesoncommonplastictypes.188

Figure3-Biobasedvs.fossil-basedplasticsandbiodegradablevs.non-biodegradableplastics.

187http://en.european-bioplastics.org/bioplastics/188http://en.european-bioplastics.org/bioplastics/


7.4.1. Oxo-degradableplasticsOxo-degradationresultsfromoxidativecleavageofmacromolecules189,inwhichadditivesareusedtofacilitatethis.190Theseplasticscanbeeitherfossil-orbio-based,however,thebioplasticsindustrydoesnotregardoxo-degradableplasticsasbeingbiodegradable.Oxo-degradableplasticsarenormallyfossilplasticswithadditivestoinitiatedegradation.

Moreknowledgeisneededtounderstandtheprocessesofdegradationandbiodegradation.Oxo-degradableplasticsareincreasinginuse,especiallyintheMiddleEast.SomecarrierbagsinNorwayaremarkedasoxo-degradable.191ThesebagsareLDPEbagsthatcontainanadditive,andwillthusbesortedasLDPEfilmattheMRFandcouldcauseproblemsintherecyclingprocess-oxo-degradablematerialcouldhavedetrimentaleffectsonsomeproductsthatmustbewrappedinvirginmaterial192.Theuseofoxo-degradablefilmshouldforthisreasonbeavoided.

7.4.2. BiodegradableplasticsSomeplasticsaredevelopedtobecompostableorbiodegradable.Theseplasticscanbeeitherfossil-orbio-based.Someproductscanalsobeamixoffossil-andbio-basedplastics,forexample,theCocaColaPETbottlesintroducedinNorway.Therearemanyproductsthatclaimtobemoreorlessdegradableorcompostable,orhavecertainproperties.Theuseoftheseplasticshassofarbeenlimited,however,furthergrowthisexpected,especiallyforpackagingapplications.Knowledgeofallkindsofdegradableplasticsandtheirimpactsisthereforeheavilydesired.

7.4.3. ProductionvolumesandapplicationsComparedtotheannualglobalplasticproductionofabout300milliontons,biodegradableandcompostableplasticsamounttoaverysmall,albeitrising,share.Thisincludesallkindsofbiobasedplasticsaswell,whichintotalamountsto1-2milliontons(in2012).

Thechartbelow,Figure4,differentiatesbetweenbiodegradableplastics(fossilorbiobased)andnon-biodegradable/biobased.Asillustratedinthefigure,themarketisslowlygrowing,mostlyforbiobasedplastics,suchasgreenPE,e.g.plasticswiththesamepropertiesasother(fossil)plastics.Thechartdoesnotincludeoxo-degradableplastics,normallyfossilplasticswithadditivestoinitiatedegradation.Thereislimitedinformationonoxo-degradableplastics.

189AccordingtoCEN/TR15351190Thestandarddefinestheprocesses,notmaterials,whichmeansthatthedefinitionofOxo-degradableplasticsisnotprovided,accordingtoDeconinck,S.,&DeWilde,B.(2013).Benefitsandchallengesofbio-andOxo-degradableplastics.Acomparativeliteraturestudy,OWSN.V,Belgium.191Forexample,carrierbagsfromtheTGRstoresinNorwayaremarkedwith“Thisbagisoxobiodegradableandwillnaturallybreakdownafter18months”.192RECOUPRecyclabilityByDesign(asiscovered,page52)http://www.recoup.org/p/130/recyclability-by-design


Figure4-Globalproductioncapacitiesofbioplastics(EuropeanBioplastics)

Biodegradable,compostableandoxo-degradableplasticsareoftenusedforcarrierbags,binbags,includingcompostbagsforfoodwaste,beveragebottles,andpackagingforcatering.Thebio-bagssoldinNorwayforfoodwasteareexamplesofstarch-blendedbags.

Thefigurebelow,Figure5,showsthatglobalproductioncapacitiesarerelatedtodifferentapplications.Bio-PET,oftencalledplant-basedbottles,isoneofthelargestapplications.Bio-PEThasthesamepropertiesasfossil-basedPET,bothregardingrecyclinganddegradation.Thesamecanbesaidaboutbio-PE,oftencalledgreenPE.GreenPEisusedtoacertainextentintheNordicmarket,forexampleastoiletpaperpackaging.GreenPEfromsugarcaneandbio-basedplasticsfromthewoodswillbemorecommoninthecomingyears.193

PLAandPLA-blendsareusedinbottles,packaging,cateringproductsandotherspecificproductsthatareexposedtolittering.Starchblendsareusedinbiobags,bagsthataredesignedforcompostingandcanbecertifiedaccordingtotheEuropeanstandardforindustrialcompostableproducts,EN13432.Horticultureandagricultureisonesectorwheretheseproductsarepromoted,forexampleformulchfilm.Thereislikelytobefurthergrowthincompostableandbiodegradableplastics,inadditiontoavarietyofdifferenttypesofsuchmaterials.

193Wik,Pär,Trioplast,Sweden,personalcommunication,presentationatPolymerdageneinNorway,September2015


Figure5-Globalproductioncapacitiesofbioplastics2012,bymarketsegments(EuropeanBioplastics).

Plasticsaredesignedtomeetcertaindefinedproperties,forexampletobecompostable.Standards,likeEN1324,areusedasatoolinthemarkettoidentifytheseproperties.Biodegradableplasticsareoftenusedforkitchenwasteandfollowthestreamtocompostorbiogasplants.InNorthernEurope,biogasplantsaremoreandmorecommon.Attheseplants,allkindsofplasticsaresortedoutandsenttoincineration.Bio-bagsarepromotedinmanycountries,whileLDPEandHDPEbagsaretaxedorbanned.Inthisway,LDPEandHDPEbagsendupintheMRFs,andaresortedoutforrecycling.However,thewell-knownNovamontbio-bag,donotcontainLDPEwhichmeansitissortedintothemixedwastefractionoraswasteforincineration.

Belowfollowsanupdatedchartonglobalproductioncapacitiesofbioplastics2016,bymaterialtype.Thebiodegradablebioplasticsamountsto24.1%ofthetotalamount.194Non-biodegradablePURamountstoasmuchas41.2%,whilenon-biodegradablePETcontributewith22.8%.Allfiguresrelatetocapacities,nottorealtonnageputonthemarket.

194EuropeanBioplastics,homepage


Figure6–Globalproductioncapacitiesofbioplastics2016,bymaterialtype.

7.4.4. SortingandrecyclingofbioplasticsBiobasedplasticsarenotnecessarilycompostableandcompostableplasticsarenotnecessarilybiobased.195Thereisalreadyavarietyofcombinations,anditseemswewillseemanymore.Thisvarietyindicatesahighdegreeofinnovation,andprobablymorechallengeswithincollection,sortingandrecycling.

In2016,Cefur-centerförforskningochutvecklinginRonneby,publishedareportunderliningthatplasticsrecyclingtodayischallengingastherearesomanydifferenttypesrequiringdifferentandindividualrecyclingtreatments.Plasticsalsodegradedifferentlyduringtheirlifetime.Theintroductionofvariousbiobasedplastics,contributestoanevenmorecomplexsituation.Therehavenotbeenenoughstudiesontheimpactofmixingdifferenttypesofplasticsandthedegradabilityofbioplastics.

ThisCefur-studydemonstratespotentialchallengesforfuturerecyclingsystemsduetothevarietyofbiobasedplasticswithsimilar,albeitnotidenticalstructuresandpropertieswithotherplastics.Solutionscouldbenewlabellingsystems,bettersortingtechnologiesandnewadditives/compatibilizersfortherecyclingprocesses.

Inseveralapplications,suchasbeveragebottlesandcarrierbags,biodegradableproductsareusedsidebysidetofossil-basedplasticproducts.Itisdifficulttoseparatebiodegradableandbiobasedplasticsfromconventionalforms.Somebiodegradableproductscanharmtheplasticrecyclingprocesssotheuseofanddisposaloftheseisheavilydebated.OnePLAbottleinthePETfractioncancontributetoseverequalityproblemsforthePETrecyclate.Inasimilarway,newbiogasplantsthatreplaceformercompostplantsdonotwantplasticsofanykindintheirprocesses.

195WorldEconomicForum,EllenMacArthurFoundationandMcKinsey&Company(2016).TheNewPlasticsEconomy-Rethinkingthefutureofplastics.Availableat:https://www.ellenmacarthurfoundation.org/assets/downloads/publications/EllenMacArthurFoundation_TheNewPlasticsEconomy_19012016.pdf


BiobasedplasticssuchasPLAcanbeseparatedfromotherplasticsusingNIRtechnology.TheNIRdetectorcanseparatePE,PPfromPLAatleast,andpotentiallyotherbiodegradableplastics.Danoneandotherindustrialplayershaveruntestsontheseproducts.196TheNIRdetectorcanbeprogrammedtoidentifybiopolymersorvariationsofpolymers(e.g.PLAorstarchblends)iftheyhaveadifferentNIRsignal.Existingsortingsystemscaneasilyidentifybio-PETanditsconventionalcounterparts.197TheideaisthattheyarecompostableandcanberecycledintonewPLAproducts.198However,justonePLAbottlesortedatPETbymistakecanharmthequalityofawholelotofPETbottles.

Thecompositionofdegradableplasticbagsandplasticfilmisoftenunknown,whichmakesitdifficultfortheNIRdetectortoidentifytheseproducts.BiodegradableproductscanconsistofLDPEfilmandthusbesortedoutintothatfractioninMRFs.Biodegradableplasticpackagingcouldendup,bymistake,indifferentplasticfractionswhichcanthenharmrecyclinginthenextstep.IntheMRF,thereisnowaytoseparateapieceofPEfilmfromPEthathasanxo-degradableadditive,becausethespectralinformationisidentical.199

IfbiodegradableordegradableplasticfilmendsupintheLDPEfilmfraction,thiswillharmtherecyclingprocessandtheend-products.ThiscandamagethevalueofLDPEregranulates.AccordingtoanEcoembesstudyinSpain,evensmallamountsofdegradablematerialintheLDPEstreaminvolveincreasedprocessingcosts.Biodegradablepolymersareincompatibleastheyhaveadifferentmeltflowindex.

Accordingtothestudy“ImpactofDegradableandOxo-FragmentablePlasticCarrierBagsonmechanicalrecycling”(TransfercenterfürKunststofftechnikGmbH,2012),“[…]aslittleas2%oxo-fragmentableordegradablematerialsintherecyclingstreamscanaffectthequalityofrecyclates,hencetheproductionofanewPE-film.Thereasonsfortheseproblemsareduetounsteadybubbleandmeltpressurevariedduringtheextrusionofnewblownfilmprocess,anddecreasedmechanicalpropertiesofallthemixesofdegradables

Itislikelythatasthequantityofbiodegradableplasticsincreases,especiallyforcarrierbags,themorecontaminationofLDPEfilmwillbeevidentintheMRF.Mechanicalprocessessuchaswindshifting,usedtoseparatetheheavyfractionsfromthelighterones,willnotbeabletoseparatethedifferentfilm-materials.200CertainreportsconcludethattheLDPEfilmfractionisruinedifmorethan2%isbiodegradableplastics.Othertestsstatethatthenumberissomewhathigher,dependingonthepropertiesintheendproduct.Somesaya10%mixisokay.201

Bioplasticscanbemechanicallyororganicallyrecycled.202Biobasedorbiodegradableplasticsareoftendesignedtobeeitherrecyclableorindustriallycompostable.Somebiobasedplastics,suchasPLAandPHA,areintheorybothrecyclableandindustriallycompostable.203ThevolumesofPLAarenotyetatasufficientleveltomakesortingeconomicallyviable.204Mostbioplasticscanbemadereadyforusein

196OliverLambertz,Tomra197EuropeanBioplastics(2015).MechanicalRecycling.Availableat:http://docs.european-bioplastics.org/2016/publications/bp/EUBP_bp_mechanical_recycling.pdf198OliverLambertz,Tomra199LucaStramare,Corepla200OliverLambertz,Tomra201OliverLambertz,Tomra202EuropeanBioplastics(2016).Bioplastics–FurtheringEfficientWasteManagement.Availableat:http://docs.european-bioplastics.org/2016/publications/fs/EUBP_fs_end-of-life.pdf203WorldEconomicForum,EllenMacArthurFoundationandMcKinsey&Company(2016).TheNewPlasticsEconomy-Rethinkingthefutureofplastics.Availableat:https://www.ellenmacarthurfoundation.org/assets/downloads/publications/EllenMacArthurFoundation_TheNewPlasticsEconomy_19012016.pdf204EuropeanBioplastics(2015).MechanicalRecycling.Availableat:http://docs.european-bioplastics.org/2016/publications/bp/EUBP_bp_mechanical_recycling.pdf


materialrecycling;however,itmayrequireadditionalsteps.PLAwillhavetogothroughanadditionalstepofpoly-condensation,oraspecialcrystallisationstage.205MaterialrecyclingofbiobasedPEandPETPETfitintoexistingrecyclingsystemsforfossil-basedplastics.206

Mepexconcludesthatthevolumesofdegradable,biodegradable,compostableandotherbiobasedplasticsstillrepresentsmallvolumesinthehouseholdwaste.Inaddition,theseproductshavesofar,justtoalimiteddegreebeencollected,sortedandrecycledwithotherplasticpackaging.Thus,thepotentialproblemsandchallengesdescribedabovehavesofarnotbeenrecognizednorhavetheyreceivedgotmuchattentioninthedebates.However,thevolumesandthenumberofalternativecompositionsareincreasing,especiallyforplasticpackagingincludingshoppingbags.Thisispartlyduetonationalbans,taxesandothermotivatedinitiatives.

AstheLDPEfilmrepresentsthemajorplasticpackagingtypeinScandinavia,thesesystemsarevulnerabletocontaminationofthiswastestream.ApossibleincreaseintheuseofdifferenttypesofdegradablefilmsrepresentthereforeacertainriskformorecontaminationandthusalessattractiveLDPE-materialforsale.Toreducethesecontaminationrisks,bettersortingtechnologiesmightbeanoption.Ontheotherhand,“stricter”sortingmightagainincreaselosses(andinvestmentsandcosts)inthesortingandwashingprocesses.Inaddition,somedegradablePE-filmisregardedimpossibletosortoutfromotherLDPE.

Asanalternative,discussedinItaly,allcompostableplasticscanbecollectedinaseparatesystem.However,sucha(small)systemjustforcompostablematerialswillprobablynotacceptotherbiodegradableandoxodegradableplastics(notcompostablebythestandard)andthusnotsolvethedescribedcontaminationproblem.Furthermore,Nordicbiogasplants,andevencompostplants,areprobablynotable(orinterested)totreatthesecompostableplastics.Thelastoptionisthenincineration,whichagainisapoorsolutionforacirculareconomy.

Atthisstage,biobased,oxo-degradable,andbiodegradableplasticscannotberecommendedaslongastheymightbecollectedasresidualwasteortheplasticwastefromhouseholds.Forindustrialuse,itisevenmoreimportanttokeepthedegradablefilmapartfromseparatecollectedLDPEfilm,asthesecollectedfilmsarenormallyenteringtherecyclingprocessdirectly.

205EuropeanBioplastics(2015).MechanicalRecycling.Availableat:http://docs.european-bioplastics.org/2016/publications/bp/EUBP_bp_mechanical_recycling.pdf206EuropeanBioplastics(2015).BenefitsofBiobasedRigidPackaging.Availableat:http://docs.european-bioplastics.org/2016/publications/bp/EUBP_bp_Rigid_Packaing.pdf


7.5. References

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7.6. ListofPersonalCommunications

Ackermans,Nina-Borealis,Austria

Arroyo,Isabel-DOWCHEMICAL,IBERIA

Brunborg,Jan-TommenGram,Norway

East,Paul-RECOUP,UK

Eie,Thomas-BAMA,Norway

Etien,Thomas-Danone,France

Flom,Atle-Døvigen,Norway

Foster,Stuart-RECOUP,UK

Furfari,Antonino-EuropeanPlasticsRecyclers,Belgium

Houlder,Graham-Sloop-Consulting,Netherlands

Jentoft,Håkon-OsloREN,Norway

Jost,Arne-MTM,Germany

Lambertz,Oliver-Tomra,Germany

Larsen,Hanne-Nofima,Norway

Lehmann,Martina-MAKSC.Germany

Leth,Lars-Linpac,Denmark

Lofthus,Sylvia-BAMA,Norway

Lystad,Henrik-AvfallNorge,Norway

Muller,Finn-TommenGram,Norway

Myhre,OleJan-Norner,Norway

Ness,AnnetteSophie-Tine,Norway

Pichler,Harald-ARA,Austria

Romen,BenedikteWilleke-Tine,Norway

Scriba,Michael,Dr.-MTM,Germany

Schmitz,Helmut-DSD,Germany

Skovly,Terje-ROAF,Norway

Storeide,EinarAassved-Unil,Norway

Strååt,Martin-Swerea,Sweden

Trømborg,Anders-RPCPromens,Norway

Trømborg,Kjersti-OrklaFoods,Norway

Vestbekken,OleKristian-Mills,Norway

Vogt,Andreas-VogtPlastics,Germany

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